24-25-3sm Carrier Application Guide and Service Manual

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 . . . . . . . . . . . . . . . . . . . . . . . . 3 Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ACCESSORIES AND DESCRIPTIONS . . . . . . . . . . . . . . 4 -- 5 Compressor Removal and Replacement . . . . . . . . . . . . . . . 32
LOW--AMBIENT GUIDELINE . . . . . . . . . . . . . . . . . . . . . . 6 -- 7 System Clean--Up After Burnout . . . . . . . . . . . . . . . . . . . . 32
LONG LINE GUIDELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CABINET ASSEMBLY & COMPONENTS . . . . . . . . . . . 8 -- 11 CHECK CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 -- 13 TROUBLESHOOTING WITH SUPERHEAT . . . . . . . . . 34 -- 43
Aluminum Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 TWO--STAGE 25HNA / 24ANA . . . . . . . . . . . . . . . . . . 44 -- 56
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 APPLICATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . 44
Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--13 MODEL PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cycle Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Make Airflow Selections For 24ANA7/25HNA6/
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 24ANA124,36,48A0032/24ANA160A0033/25HNA924,36,48A0
032,25HNA960A0033 With Serial Number 3809 And Later
Time--Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Using Non--communicating (Non--infinity) Thermostats . . . . . 45
PRESSURE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Airflow Selection for FV4 Fan Coils for 24ANA1, 24ANA7,
DEFROST THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . 15 25HNA6, 25HNA9 with serial number 3809 and later Using
Non--Communicating (Non--Infinity) Thermostats . . . . . . . . . . 45
DEFROST CONTROL BOARD . . . . . . . . . . . . . . . . . . . 15 -- 17
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 45--46
SYSTEM FUNCTION AND
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . 17--18 CHECK CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
COPELAND SCROLL COMPRESSOR . . . . . . . . . . . . . 19--22 SYSTEM FUNCTION AND
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . 47--50
Compressor Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 51--55
Mechanical Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--20
TWO--STAGE 25HNB / 24ANB . . . . . . . . . . . . . . . . . . . 56--66
Electrical Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21--22
APPLICATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . 56
REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . 22--23
MODEL PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Airflow Selections For 24ANB7 / 25HNB6 / 24ANB1 /25HNB9
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Using Non--Communicating (Non--infinity) Thermostats . . . . . 57
Servicing Systems on Roofs With Synthetic Materials . . . . 23
Airflow Selection For FV4 Fan Coils For 24ANB1, 24ANB7,
Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 25HNB6, 25HNB9 Using Non--Communicating (non--Infinity)
Service Valves and Pump down . . . . . . . . . . . . . . . . . . 24--26 Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Liquid Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 57--55
Suction Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CHECK CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 SYSTEM FUNCTION AND
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . 59--62
Thermostatic Expansion Valve (TXV) . . . . . . . . . . . . . 29--30
TABLE OF CONTENTS (CONTINUED)
TWO STAGE NON--COMMUNICATING Airflow Selection for VS Furnaces (non--comm) . . . . . . . . . . . 70

24ACB7 / 25HCB6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67--69 Airflow Selection for FV4C Fan Coils Using Non--Comm
OPERATING AMBIENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 (Non--Infinity) Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Airflow Selections (ECM Furnaces) . . . . . . . . . . . . . . . . . . . . . 67 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 71--72
Airflow Selection for Variable Speed Furnaces CHECK CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
(non--communicating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Airflow Selection for FV4C Fan Coils SYSTEM FUNCTION AND SEQUENCE OF OPERATION . 74
(non--communicating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SYSTEM FUNCTION AND
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 68 CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 78
CHECK CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 PURON QUICK REFERENCE GUIDE . . . . . . . . . . . . . . . . . 79
TWO STAGE COMMUNICATING AC TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . 80
24APA7/25HPA6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70--77 HP TROUBLESHOOTING CHART -- HEATING CYCLE . . 81
OPERATING AMBIENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 HP TROUBLESHOOTING CHART -- COOLING CYCLE . . 82
MODEL PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 INDEX OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Airflow Selections for ECM Furnaces (non--comm) . . . . . . . . . 70
UNIT IDENTIFICATION
Troubleshooting Charts for Air Conditioners and Heat Pumps are This section explains how to obtain the model and serial number
provided in the appendix at back of this manual. They enable the from unit rating plate. These numbers are needed to service and
service technician to use a systematic approach to locating the repair the Puronr and R--22 air conditioner or heat pump. Model
cause of a problem and correcting system malfunctions. and serial numbers can be found on unit rating plate.
AIR CONDITIONER AND HEAT PUMP MODEL NUMBER NOMENCLATURE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
2 4 A B A 3 3 6 A 0 0 3 0 0 0 0
Major Cooling Minor Parts
Series Family Tier SEER Variations Open Open Voltage Packaging Open
Series Capacity (Tons) Series Identification
0 = Recip.
18 = 1-- 1/2
3 = 13 SEER 1 = 575-- 3 1 = Scroll
B = Base / Comfort 24 = 2 A = Standard
5 = 15 SEER 3 = 208/230-- 1 2 = Staged
C = Comfort / 30 = 2-- 1/2 C = Coastal 0=
24 = AC A = A/C A,B = Puron 6 = 16 SEER 0 = Not 0 = Not 5 = 208/230-- 3 0 = Domestic Recip. 0 = Not
Performance 36 = 3 F = Full Featured Initial
25 = HP H = HP R,S = R22 8 = 18 SEER Defined Defined 6 = 460-- 3 1 = Import 3 = Staged Defined
P = Performance 42 = 3-- 1/2 G = Dense Grill Series
1 = 21 SEER 7 = 230-- 1-- 50 Scroll
N = Infinity 48 = 4 L = Louvers
7 = 17 SEER 9 = 400-- 3-- 50 4 = Other
60 = 5
Compr.
SERIAL NUMBER NOMENCLATURE
01 06 E 00001
Week of Manufacture Serial Number
Manufacturing Site
E = Collierville TN
Year of Manufacture X = Monterey Mexico
2
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 Data (PD). DO
practices and unit Installation Instructions, and in compliance with NOT DEVIATE FROM PD. Consult unit Installation Instructions
all national and local codes. Power should be turned off when for detailed information.
servicing or repairing electrical components. Extreme caution
should be observed when troubleshooting electrical components Add--On Replacement (Retrofit) -- R22 to Puron
with power on. Observe all warning notices posted on equipment Specifications for these units in the add--on replacement/retrofit
and in instructions or manuals. market require change--out of outdoor unit, metering device, and
all capillary tube coils. Change--out of indoor coil is recommended.
! WARNING There can be no deviation.
1. If system is being replaced due to compressor electrical
UNIT OPERATION AND SAFETY HAZARD failure, assume acid is in system. If system is being replaced
for any other reason, use approved acid test kit to determine
Failure to follow this warning could result in personal
acid level. If even low levels of acid are detected install
injury or equipment damage.
factory approved, 100 percent activated alumina
Puronr (R--410A) systems operate at higher pressures than suction--line filter drier in addition to the factory supplied
standard R--22 systems. Do not use R--22 service equipment liquid--line filter drier. Remove the suction line filter drier as
or components on Puronr equipment. Ensure service soon as possible, with a maximum of 72 hr.
equipment is rated for Puronr.
2. Drain oil from low points or traps in suction--line and
evaporator if they were not replaced.
Refrigeration systems contain refrigerant under pressure. Extreme
3. Change out indoor coil or verify existing coil is listed in the
caution should be observed when handling refrigerants. Wear
Product Data Digest.
safety glasses and gloves to prevent personal injury. During normal
system operations, some components are hot and can cause burns. 4. Unless indoor unit is equipped with a Puronr approved
Rotating fan blades can cause personal injury. Appropriate safety metering device, change out metering device to factory
considerations are posted throughout this manual where potentially supplied or field--accessory device specifically designed for
dangerous techniques are addressed. Puronr.
5. Replace outdoor unit with Puronr outdoor unit.
INTRODUCTION 6. Install factory--supplied liquid--line filter drier.
This document provides required system information necessary to
install, service, repair or maintain the family air conditioners and
heat pumps using R22 or Puron refrigerant. ! CAUTION
Refer to the unit Product Data for rating information, electrical
data, required clearances, additional component part numbers and UNIT DAMAGE HAZARD
related pre--sale data. Installation Instructions are also available per Failure to follow this caution may result in equipment
specific models. damage or improper operation.
Information in this document refers to units produced in 2006 and Never install suction--line filter drier in the liquid--line of a
later. For products produced prior to this date, please refer to Puronr system.
Service Manual number 38--10SM for products containing R22
7. If suction--line filter drier was installed for system clean up,
refrigerant and Service Manual 38--11SM for products containing
operate system for 10 hr. Monitor pressure drop across drier.
Puron refrigerant.
If pressure drop exceeds 3 psig, replace suction--line and
liquid--line filter driers. Be sure to purge system with dry
nitrogen and evacuate when replacing filter driers. Continue
to monitor pressure drop across suction--line filter drier.
After 10 hr of runtime, remove suction--line filter drier and
replace liquid--line filter drier. Never leave suction--line
filter drier in system longer than 72 hr (actual time).
8. Charge system. (See unit information plate.)
Seacoast
Coastal units are available in selected models and sizes of Air
Conditioners and Heat Pumps. These units have protection to help
resist the corrosive coastal environment. Features include:
S Armor plate fins and epoxy coated coils
S Complete baked--on paint coverage
(both sides of external sheet metal and grilles)
S Paint coated screws
Coastal environments are considered to be within 2 miles of the
ocean. Salt water can be carried as far away as 2 miles from the
coast by means of sea spray, mist or fog. Line--of--sight distance
from the ocean, prevailing wind direction, relative humidity,
wet/dry time, and coil temperatures will determine the severity of
corrosion potential in the coastal environment.
3
ACCESSORIES
Table 1—Required Field--Installed Accessories for Air Conditioners

REQUIRED FOR
REQUIRED FOR LOW --- AMBIENT REQUIRED FOR
SEA COAST
ACCESSORY COOLING APPLICATIONS LONG LINE APPLICA-
APPLICATIONS
(Below 55°F/12.8_C) TIONS*
(Within 2 miles/3.22 km)
Ball Bearing Fan Motor Yes {} No No
Compressor Start Assist Capacitor and Relay Yes** Yes No
Crankcase Heater Yes } Yes } No
Evaporator Freeze Thermostat Yes } No No
Hard Shut--- Off TXV Yes Yes Yes
Liquid Line Solenoid Valve No No No
Motor Master® or Low--- ambient Pressure Switch Yes } No No
Support Feet Recommended No Recommended
Winter Start Control Yes } No No
* For tubing line sets between 80 and 200 ft. (24.38 and 60.96 m) and/or 35 ft. (10.7 m) vertical differential, refer to Residential Piping and Longline Guideline.
{ Additional requirement for Low---Ambient Controller (full modulation feature) MotorMasterr Control.
} Infinity 2 ---stage units come standard with this accessory.
** Not required on 2 ---stage
Table 2—Required Field--Installed Accessories for Heat Pumps

REQUIRED FOR
REQUIRED FOR LOW --- AMBIENT REQUIRED FOR
SEA COAST APPLICA-
ACCESSORY COOLING APPLICATIONS LONG LINE APPLICA-
TIONS (Within 2 miles /
(Below 55°F / 12.8°C) TIONS*
3.22 km)
Accumulator Standard Standard Standard
Ball Bearing Fan Motor Yes {} No No
Compressor Start Assist Capacitor and Relay Yes ** Yes No
Crankcase Heater Yes } Yes } No
Evaporator Freeze Thermostat Yes } No No
Hard Shutoff TXV Yes Yes Yes
Isolation Relay Yes No No
See Long---Line Application
Liquid Line Solenoid Valve No No
Guideline
Motor Master® Control or
Yes } No No
Low Ambient Switch
Support Feet Recommended No Recommended
* For tubing line sets between 80 and 200 ft. (24.38 and 60.96 m) and/or 20 ft. (6.09 m) vertical differential, refer to Residential Piping and Longline Guideline.
{ Additional requirement for Low---Ambient Controller (full modulation feature) MotorMasterr Control.
} Infinity 2 ---stage units come standard with this accessory.
** Not required on 2 ---stage
4
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 includes valve, adapter tubes, and external equalizer tube. Hard
compressor to keep the lubricant warm during off cycles. Improves shut off types are available.
compressor lubrication on restart and minimizes the chance of Usage Guideline:
liquid slugging. Accessory required to meet ARI rating and system
Usage Guideline: reliability, where indoor not equipped.
Required in low ambient cooling applications. Hard shut off TXV or LLS required in heat pump
Required in long line applications. long line applications.
Suggested in all commercial applications. Required for use on all zoning systems.
2. Evaporator Freeze Thermostat 7. Time--Delay Relay
An SPST temperature--actuated switch that stops unit operation An SPST delay relay which briefly continues operation of indoor
when evaporator reaches freeze--up conditions. blower motor to provide additional cooling after the compressor
Usage Guideline: cycles off.
Required when low ambient kit has been added. NOTE: Most indoor unit controls include this feature. For those
3. Isolation Relay that do not, use the guideline below.
An SPDT relay which switches the low--ambient controller out of Usage Guideline:
the outdoor fan motor circuit when the heat pump switches to Accessory required to meet ARI rating, where indoor
heating mode. not equipped.
Usage Guideline: 8. Wind Baffle
Required in all heat pumps where low ambient kit has Use only in installations where high winds are prevalent to prevent
been added cross currents from causing abnormal control operation. For
4. Low--Ambient Pressure Switch construction, refer to Fig. 1 and Fig. 2.
A fan--speed control device activated by a temperature sensor, NOTE: When wind baffles are used, raising unit off of mounting
designed to control condenser fan motor speed in response to the pad with 4--in. support feet or unit risers is REQUIRED. This
saturated, condensing temperature during operation in cooling provides better airflow for moderate and high ambient
mode only. For outdoor temperatures down to --20_F (--28.9_C), it temperatures.
maintains condensing temperature at 100_F ± 10_F (37.8_C ± 9. Winter Start Control
12_C). This control is designed to alleviate nuisance opening of the
Usage Guideline: low--pressure switch by bypassing it for the first 3 minutes of
A Low Ambient Controller must be used when operation. This control is for AC units operating in low ambient
cooling operation is used at outdoor temperatures cooling but is not required for Heat Pumps. Heat pumps have a
below 55_F (12.8_C). loss of charge switch rather than a low pressure switch and
Suggested for all commercial applications. nuisance trips should not be an issue.
5. Outdoor Air Temperature Sensor
Designed for use with Carrier Thermostats listed in this
publication. This device enables the thermostat to display the
outdoor temperature. This device is required to enable special
thermostat features such as auxiliary heat lock out.
Usage Guideline:
Suggested for all Carrier thermostats listed in this
publication.
5
LOW--AMBIENT COOLING GUIDELINE
The minimum operating temperature for these units in cooling Comfort Series models and Fig. 2 for Deluxe models. First
mode is 55_F/12.7_C outdoor ambient without additional production of Performance units are capable of low ambient
accessories. This equipment may be operated in cooling mode at cooling only with pressure switch or Infinity UI control. Motor
ambient temperatures below 55_F/12.7_C when the accessories Master was not available. See most current Product Data for
listed in Table 1 or 2 are installed. Wind baffles are required when updates. Infinity Series 2--Stage units are capable of low ambient
operating in cooling mode at ambients below 55_F/12.7_C. Refer cooling only with Infinity UI control.
to Fig. 1 for wind baffle construction details for Base through
A06450
Entry, Mid Tier, and 4 Sided Deluxe Units (in.)

UNIT
AA UNIT HEIGHT A B C ---1 C ---2 C ---3 D
SIZE
25--- 5/16 20--- 3/8 10--- 1/16
28--- 11/16 23--- 13/16 11--- 3/4
32--- 1/8 27--- 3/16 13--- 1/2
Mini Base 23--- 1/8 35--- 1/2 30--- 5/8 15--- 3/16 1--- 5/16 8--- 1/4 3--- 1/2 39--- 1/4
38--- 15/16 34 16--- 7/8
42--- 5/16 37--- 3/8 18--- 9/16
45--- 11/16 40--- 13/16 20--- 1/4
25 20--- 3/8 10--- 1/16
28--- 7/16 23--- 13/16 11--- 3/4
31--- 13/16 27--- 3/16 13--- 1/2
Small 25--- 3/4 35--- 1/4 30--- 5/8 15--- 3/16 3--- 15/16 10--- 7/8 6--- 1/8 41--- 7/8
38--- 5/8 34 16--- 7/8
42 37--- 3/8 18--- 9/16
45--- 7/16 40--- 13/16 20--- 1/4
25--- 1/2 20--- 3/8 10--- 1/16
28--- 15/16 23--- 13/16 11--- 3/4
32--- 5/16 27--- 3/16 13--- 1/2
Medium 31--- 1/4 35--- 3/4 30--- 5/8 15--- 3/16 9--- 3/8 16--- 5/16 11--- 9/16 47--- 3/8
39--- 1/8 34 16--- 7/8
42--- 1/2 37--- 3/8 18--- 9/16
45--- 15/16 40--- 13/16 20--- 1/4
25--- 1/2 20--- 3/8 10--- 1/16
28--- 15/16 23--- 13/16 11--- 3/4
32--- 5/16 27--- 3/16 13--- 1/2
Large 35 35--- 3/4 30--- 5/8 15--- 3/16 13--- 3/16 20--- 1/8 15--- 3/8 51--- 1/8
39--- 1/8 34 16--- 7/8
42--- 1/2 37--- 3/8 18--- 9/16
45--- 15/16 40--- 13/16 20--- 1/4
Fig. 1 – Base / Mid--Tier / Deluxe (4--sided) Baffle Assembly
6
BAFFLE-1
MA
TL: 20 GA STEEL
A06230
3 Sided Deluxe Units (in.)
UNIT
AA UNIT HEIGHT 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
47--- 5/16 40--- 13/16 20--- 3/8
Fig. 2 – Deluxe (3--sided) Baffle Assembly and Dimensions
7
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).
Infinity / Deluxe
Comfort --- Puron with Wrap Grille Base --- R22 with Wrap Grille
Performance
Performance / Infinity Base --- Puron

(no longer in production) (no longer in production) Base --- R22
(no longer in production)
Fig. 3 – Cabinet Designs
8
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 top.
4. Reverse sequence for reassembly.
1. Should the unit height allow components to be accessed
from the top of the unit, follow procedures for removing fan 5. Prior to applying power, check that fan rotates freely.
motor assembly. Access components through the top cap. Control Box Cover—Base Products
2. Large components may not be removed easily without This panel contains much of the same information as the
having access from the top and side. Side access may allow information plate mentioned previously, but is designed only to
procedures such as brazing, cutting, and removal easier. cover the control box.
Follow procedures below: Remove Top Cover—Base Products
a. Follow procedures to remove the fan motor assembly. 1. Turn off all power to outdoor an indoor units.
b. Air conditioning units only, remove the screws from the top 2. Remove 5 screws holding top cover to coil grille and coil
of the electrical control panel. (Heat pumps will not have tube sheet.
screws holding the electrical control panel in place at the top 3. Remove 2 screws holding control box cover.
once the control box cover has been removed.)
4. Remove 2 screws holding information plate.
c. Remove the base pan screws holding the control panel and
5. Disconnect fan motor wires, cut any wire ties, and move
lift off the unit.
wires out of control box and through tube clamp on back of
Certain maintenance routines and repairs require removal of control box.
cabinet panels.
6. Lift top cover from unit.
Remove Top Cover -- Mid--Tier / Deluxe
1. Turn off all power to outdoor and indoor units.
Remove Fan Motor Assembly—Base Products
2. Remove access panel.
1. Perform items 1, 3, 4, and 5 above. (Note: item 2 is not
3. Remove information plate. required.)
4. Disconnect fan motor wires and cut wire ties. Remove wires 2. Remove 4 screws holding wire basket to top cover.
from control box. Refer to unit wiring label.
3. Lift wire basket from unit.
5. Remove screws holding top cover to louver panels.
4. Remove nuts holding fan motor to wire basket.
6. Lift top cover from unit.
5. Remove motor and fan blade assembly.
6. Pull wires through wire raceway to change motor.
4--sided deluxe units employ one louver spacer on each of the four
sides to prevent louver movement during operation. The louver
spacers are trapped between the coil surface and louver at the 8. Prior to applying power, check that fan rotates freely.
approximate center of each side (See Fig. 4). This louver spacer
should be present and, if dislodged during shipment, must be
reinstalled before unit is placed into operation.
Louver Spacer
A11380
Fig. 4 – Louver Spacer Location
9
Base and Comfort Series AC Control Box
Base and Comfort HP Control Box
Fig. 5 – Base and Comfort Series Control Box Identification
10
Labeling
The wiring schematic, sub--cooling charging tables with
instructions, and warning labels. Refer to Fig. 6 for label location.
Fig. 6 – Figure Labels
11
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
! WARNING voltage at coil with voltmeter. Reading should be between
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
Failure to follow this warning could result in personal injury contactor.
or death. 4. With high--voltage power off and contacts pulled in, check
Exercise extreme caution when working on any electrical for continuity across contacts with ohmmeter. A very low or
components. Shut off all power to system prior to 0 resistance should be read. Higher readings could indicate
troubleshooting. Some troubleshooting techniques require burned or pitted contacts which may cause future failures.
power to remain on. In these instances, exercise extreme Capacitor
caution to avoid danger of electrical shock. ONLY TRAINED
WARNING
SERVICE PERSONNEL SHOULD PERFORM
ELECTRICAL TROUBLESHOOTING. !
ELECTRICAL SHOCK HAZARD
Aluminum Wire Failure to follow this warning could result in personal injury
or equipment damage.
! 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
UNIT OPERATION AND SAFETY HAZARD when working near capacitors. With power off, discharge
Failure to follow this caution may result in equipment stored energy by shorting across the capacitor terminals with a
damage or improper operation. 15,000--ohm, 2--watt resistor.
Aluminum wire may be used in the branch circuit (such as NOTE: If bleed resistor is wired across start capacitor, it must be
the circuit between the main and unit disconnect), but only disconnected to avoid erroneous readings when ohmmeter is
copper wire may be used between the unit disconnect and the
applied across capacitor. (S)
unit.
Whenever aluminum wire is used in branch circuit wiring with this
unit, adhere to the following recommendations.
! WARNING
Connections must be made in accordance with the National
Electrical Code (NEC), using connectors approved for aluminum
wire. The connectors must be UL approved (marked Al/Cu with Failure to follow this warning could result in personal injury
the UL symbol) for the application and wire size. The wire size or equipment damage.
selected must have a current capacity not less than that of the Always check capacitors with power off. Attempting to
copper wire specified, and must not create a voltage drop between troubleshoot a capacitor with power on can be dangerous.
service panel and unit in excess of 2 of unit rated voltage. To Defective capacitors may explode when power is applied.
prepare wire before installing connector, all aluminum wire must Insulating fluid inside is combustible and may ignite, causing
be “brush--scratched” and coated with a corrosion inhibitor such as burns.
Pentrox A. When it is suspected that connection will be exposed to
moisture, it is very important to cover entire connection completely Capacitors are used as a phase--shifting device to aid in starting
to prevent an electrochemical action that will cause connection to certain single--phase motors. Check capacitors as follows:
fail very quickly. Do not reduce effective size of wire, such as 1. With power off, discharge capacitors as outlined above.
cutting off strands so that wire will fit a connector. Proper size Disconnect capacitor from circuit. Put ohmmeter on R X
connectors should be used. Check all factory and field electrical 10k scale. Using an analog ohmmeter, check each terminal
connections for tightness. This should also be done after unit has to ground (use capacitor case). Discard any capacitor which
reached operating temperatures, especially if aluminum conductors measures 1/2 scale deflection or less. Place ohmmeter leads
are used. across capacitor and place on R X 10k scale. Meter should
jump to a low resistance value and slowly climb to higher
Contactor value. Failure of meter to do this indicates an open
The contactor provides a means of applying power to unit using capacitor. If resistance stays at 0 or a low value, capacitor is
low voltage (24v) from transformer in order to power contactor internally shorted.
coil. Depending on unit model, you may encounter single-- or 2. Capacitance testers are available which will read value of
double--pole contactors. Exercise extreme caution when capacitor. If value is not within ±10 percent value stated on
troubleshooting as 1 side of line may be electrically energized. The capacitor, it should be replaced. If capacitor is not open or
contactor coil is powered by 24vac. If contactor does not operate: shorted, the capacitance value is calculated by measuring
1. With power off, check whether contacts are free to move. voltage across capacitor and current it draws.
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
! WARNING
reading is normal. Do not look for a specific value, as ELECTRICAL SHOCK HAZARD
different part numbers will have different resistance values.
Failure to follow this warning could result in personal injury
or death.
Exercise extreme caution when taking readings while power is
on.
12
Use following formula to calculate capacitance: With high--voltage power off, attach voltmeter leads across T1 and
Capacitance (mfd)= (2650 X amps)/volts T3, and set thermostat so that Y terminal is energized. Make sure
3. Remove any capacitor that shows signs of bulging, dents, or all protective devices in series with Y terminal are closed.
leaking. Do not apply power to a defective capacitor as it Voltmeter should read 24v across T1 and T3. With 24v still
may explode. applied, move voltmeter leads to T2 and T3. After 5 ± 2 minutes,
voltmeter should read 24v, indicating control is functioning
Sometimes under adverse conditions, a standard run capacitor in a normally. If no time delay is encountered or device never times out,
system is inadequate to start compressor. In these instances, a start change control.
assist device is used to provide an extra starting boost to
compressor motor. This device is called a positive temperature Crankcase Heater
coefficient (PTC) or start thermistor. It is a resistor wired in parallel Crankcase heater is a device for keeping compressor oil warm. By
with the run capacitor. As current flows through the PTC at keeping oil warm, refrigerant does not migrate to and condense in
start--up, it heats up. As PTC heats up, its resistance increases compressor shell when the compressor is off. This prevents flooded
greatly until it effectively lowers the current through itself to an starts which can damage compressor.
extremely low value. This, in effect, removes the PTC from the On units that have a single--pole contactor, the crankcase heater is
circuit. wired in parallel with contactor contacts and in series with
After system shutdown, resistor cools and resistance value returns compressor. (See Fig. 8.) When contacts open, a circuit is
to normal until next time system starts. Thermistor device is completed from line side of contactor, through crankcase heater,
adequate for most conditions, however, in systems where off cycle through run windings of compressor, and to other side of line.
is short, device cannot fully cool and becomes less effective as a When contacts are closed, there is no circuit through crankcase
start device. It is an easy device to troubleshoot. Shut off all power heater because both leads are connected to same side of line. This
to system. allows heater to operate when system is not calling for cooling.
Check thermistor with ohmmeter as described below. Shut off all The heater does not operate when system is calling for cooling.
power to unit. Remove PTC from unit. Wait at least 10 minutes for CRANKCASE HTR
TEMP SWITCH
PTC to cool to ambient temperature.
Measure resistance of PTC with ohmmeter. BLK BLK BLK BLK
The cold resistance (RT) of any PTC device should be
approximately 100--180 percent of device ohm rating.
11 21
12.5--ohm PTC = 12.5--22.5 ohm resistance (beige color)
If PTC resistance is appreciably less than rating or more than 200 A97586
percent higher than rating, device is defective. Fig. 8 – Wiring for Single--Pole Contactor
The crankcase heater is powered by high--voltage power of unit.
Use extreme caution troubleshooting this device with power on.
The easiest method of troubleshooting is to apply voltmeter across
crankcase heater leads to see if heater has power. Do not touch
heater. Carefully feel area around crankcase heater. If warm,
crankcase heater is probably functioning. Do not rely on this
method as absolute evidence heater is functioning. If compressor
has been running, the area will still be warm.
With 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.
Time--Delay Relay
A94006 The TDR is a solid--state control, recycle delay timer which keeps
Fig. 7 – Capacitors indoor blower operating for 90 sec after thermostat is satisfied.
Cycle Protector This delay enables blower to remove residual cooling in coil after
compression shutdown, thereby improving efficiency of system.
Carrier thermostats have anti--cycle protection built in to protect the The sequence of operation is that on closure of wall thermostat and
compressor. Should a non--Carrier stat be utilized, it is at end of a fixed on delay of 1 sec, fan relay is energized. When
recommended to add a cycle protector to the system. Solid--state thermostat is satisfied, an off delay is initiated. When fixed delay of
cycle protector protects unit compressor by preventing short 90 ± 20 sec is completed, fan relay is de--energized and fan motor
cycling. After a system shutdown, cycle protector provides for a 5 stops. If wall thermostat closes during this delay, TDR is reset and
± 2--minute delay before compressor restarts. On normal start--up, a fan relay remains energized. TDR is a 24v device that operates
5--minute delay occurs before thermostat closes. After thermostat within a range of 15v to 30v and draws about 0.5 amps. If the
closes, cycle protector device provides a 3--sec delay. blower runs continuously instead of cycling off when the fan
Cycle protector is simple to troubleshoot. Only a voltmeter capable switch is set to AUTO, the TDR is probably defective and must be
of reading 24v is needed. Device is in control circuit, therefore, replaced.
troubleshooting is safe with control power (24v) on and
high--voltage power off.
13
Pressure Switches High--Pressure Switch (AC & HP)
Pressure switches are protective devices wired into control circuit The high--pressure switch is located in liquid line and protects
(low voltage). They shut off compressor if abnormally high or low against excessive condenser coil pressure. It opens around 610 or
pressures are present in the refrigeration circuit. Puron pressure 670 psig for Puron and 400 psig for R22 (+/-- 10 for both).
switches are specifically designed to operate with Puronr systems. Switches close at 298 (+/-- 20) psig for R--22 and 420 or 470 (+/--
R--22 pressure switches must not be used as replacements for the 25) psig for Puron. High pressure may be caused by a dirty
Puronr air conditioner or heat pump. Puronr pressure switches are condenser coil, failed fan motor, or condenser air re--circulation.
identified by a pink stripe down each wire. To check switch:
Low--Pressure Switch (AC Only) 1. Turn off all power to unit.
The low--pressure switch is located on suction line and protects 2. Disconnect leads on switch.
against low suction pressures caused by such events as loss of 3. Apply ohmmeter leads across switch. You should have
charge, low airflow across indoor coil, dirty filters, etc. It opens on continuity on a good switch.
a pressure drop at about 50 psig for Puron and about 27 for R22. If NOTE: Because these switches are attached to refrigeration system
system pressure is above this, switch should be closed. To check
under pressure, it is not advisable to remove this device for
switch:
troubleshooting unless you are reasonably certain that a problem
1. Turn off all power to unit. exists. If switch must be removed, remove and recover all system
2. Disconnect leads on switch. charge so that pressure gauges read 0 psi. Never open system
3. Apply ohmmeter leads across switch. You should have without breaking vacuum with dry nitrogen.
continuity on a good switch.
NOTE: Because these switches are attached to refrigeration system
under pressure, it is not advisable to remove this device for
! CAUTION
troubleshooting unless you are reasonably certain that a problem
PERSONAL INJURY HAZARD
exists. If switch must be removed, remove and recover all system
charge so that pressure gauges read 0 psi. Never open system Failure to follow this caution may result in personal injury.
without breaking vacuum with dry nitrogen. Wear safety glasses, protective clothing, and gloves when
handling refrigerant.
! CAUTION To replace switch:
1. Apply heat with torch to solder joint and remove switch.
Failure to follow this caution may result in personal injury.
Wear safety glasses, protective clothing, and gloves when
! CAUTION
handling refrigerant. PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal injury.
To replace switch:
Wear safety glasses when using torch. Have quenching
1. Apply heat with torch to solder joint and remove switch.
cloth available. Oil vapor in line may ignite when switch is
removed.
! CAUTION
2. Braze in 1/4--in. flare fitting and replace pressure switch.
Loss of Charge Switch (HP Only)
Failure to follow this caution may result in personal injury. Located on liquid line of heat pump only, the liquid line pressure
Wear safety glasses when using torch. Have quenching cloth switch functions similar to conventional low--pressure switch.
available. Oil vapor in line may ignite when switch is Because heat pumps experience very low suction pressures during
removed. normal system operation, a conventional low--pressure switch
cannot be installed on suction line. This switch is installed in liquid
2. Braze in 1/4--in. flare fitting and screw on replacement line instead and acts as loss--of--charge protector. The liquid--line is
pressure switch. the low side of the system in heating mode. It operates identically
to low--pressure switch except it opens at 23 (+/-- 5) psig for Puron
and 7 (+/-- 5) psig for R22 and closes at 55 (+/-- 5) psig for Puron
and 22 (+/-- 5) for R22 Two--stage heat pumps have the
low--pressure switch located on the suction line. The two--stage
control board has the capability to ignore low--pressure switch trips
during transitional (defrost) operation to avoid nuisance trips.
Troubleshooting and removing this switch is identical to
procedures used on other switches. Observe same safety
precautions.
14
Defrost Thermostat Heating Sequence of Operation
Defrost thermostat signals heat pump that conditions are right for On a call for heating, thermostat makes R--Y, and R--G. Circuit
defrost or that conditions have changed to terminate defrost. It is a R--Y sends low voltage through the safeties and energizes the
thermally actuated switch clamped to outdoor coil to sense its contactor, which starts the compressor and energizes the T1
temperature. Normal temperature range is closed at 30_ ± 3_F and terminal on the circuit board. The T1 terminal energizes the defrost
open at 65_ ± 5_F. Defrost thermostats are used in Base and logic. This will energize the OF2 fan relay start the outdoor motor.
Comfort models, a coil temperature thermistor is used in Preferred The T1 terminal must be energized for defrost to function.
and Infinity series units. When the cycle is complete, R--Y is turned off and the compressor
FEEDER TUBE and outdoor fan should stop. There is no compressor delay built
into this control.
STUB TUBE
Defrost Sequence (HK32EA001)
The defrost control is a time/temperature control that has field
selectable settings of 30, 60, and 90 minutes. These represent the
amount of time that must pass after closure of the defrost
thermostat before the defrost sequence begins.
The defrost thermostat senses coil temperature throughout the
heating cycle. When the coil temperature reaches the defrost
thermostat setting of approximately 32ºF, it will close, which
DEFROST energizes the DFT terminal and begins the defrost timing sequence.
THERMOSTAT When the DTF has been energized for the selected time, the defrost
cycle begins, and the control shifts the reversing valve into cooling
A97517
position, and turns the outdoor fan off. This shifts hot gas flow into
Fig. 9 – Defrost Thermostat Location the outdoor coil which melts the frost from the coil. The defrost
Check Defrost Thermostat cycle is terminated when defrost thermostat opens at approximately
There is a liquid header with a brass distributor and feeder tube 65ºF, or automatically after 10 minutes.
going into outdoor coil. At the end of 1 of the feeder tubes, there is
a 3/8--in. OD stub tube approximately 3 in. long. (See Fig. 9.) The
defrost thermostat should be located on stub tube. Note that there is
only 1 stub tube used with a liquid header, and on most units it is
the bottom circuit.
NOTE: The defrost thermostat must be located on the liquid side OUTDOOR FAN
of the outdoor coil on the bottom circuit and as close to the coil as RELAY
possible.
Defrost Control Board
Troubleshooting defrost control involves a series of simple steps
HK32EA001
that indicate whether or not board is defective.
NOTE: This procedure allows the service technician to check DEFROST THERMOSTAT
control board and defrost thermostat for defects. First, troubleshoot MUST BE CLOSED BEFORE
DEFROST TIMER BEGINS
to make sure unit operates properly in heating and cooling modes.
This ensures operational problems are not attributed to the defrost
control board. T1 - ENABLES DEFROST
TIMER. MUST BE
Y OUTPUT TO PRESSURE
SWITCHES AND CONTACTOR
ENERGIZED FOR
HK32EA001 Defrost Control DEFROST TIMER
TO START
The HK32EA001 defrost control is used in all Base series heat C - COMMON
pump models 25HBA and 25HBR. Its features include selectable O - REVERSING VALVE
defrost intervals of 30, 60, 90 minutes, and standard defrost speed
up capability. This section describes the sequence of operation and
trouble shooting methods for this control.
Cooling Sequence of Operation
On a call for cooling, thermostat makes R--O, R--Y, and R--G. SPEEDUP
Circuit R--O energizes reversing valve switching it to cooling THERMOSTAT INPUTS

position. Circuit R--Y sends low voltage through the safeties and A05332
energizes the contactor, which starts the compressor and energizes Fig. 10 – HK32EA001 Defrost Control
the T1 terminal on the circuit board. This will energize the OF2 fan
relay which starts the outdoor fan motor.
When the cycle is complete, R--Y is turned off and compressor and
outdoor fan should stop. With Carrier thermostats, the O terminal
remains energized in the cooling mode. If the mode is switched to
heat or Off, the valve is de--energized. There is no compressor
delay built into this control.
15
Troubleshooting (HK32EA001) 3. If all voltages are present and unit will still not run defrost,
If outdoor unit will not run: remove thermostat pigtail harness from board and perform
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 should have 24
(HK32EA001):
volts if Y input is energized. This output goes through the
pressure switches and to the contactor. If 24 volts is present 1. Turn thermostat to OFF. Shut off all power to outdoor unit.
on the Y spade terminal, and the contactor is not closed, 2. Remove control box cover for access to electrical
check voltage on contactor coil. If no voltage is present, components and defrost control board.
check for opened pressure switch. 3. Disconnect defrost thermostat leads from control board, and
3. If voltage is present and contactor is open, contactor may be connect to ohmmeter. Thermostat leads are black, insulated
defective. Replace contactor if necessary. wires connected to DFT and R terminals on control board.
4. If contactor is closed and unit will still not run, check Resistance reading may be zero (indicating closed defrost
wiring, capacitor and compressor thermostat), or infinity (∞ for open thermostat) depending
Defrost Speedup on outdoor temperature.
4. Jumper between DFT and R terminals on control board as
To test the defrost function on these units, speed up pins are
shown in Fig. 10.
provided on the circuit board. To force a defrost cycle, the defrost
thermostat must be closed, or the defrost thermostat pins must be 5. Disconnect outdoor fan motor lead from OF2. Tape lead to
jumpered. Follow the steps below to force a defrost cycle: prevent grounding.
1. Jumper the DFT input 6. Turn on power to outdoor unit.
2. Short the speed up pins. This speeds up the defrost timer by 7. Restart unit in heating mode, allowing frost to accumulate
a factor of 256. The longer the defrost interval setting, the on outdoor coil.
longer the pins must be shorted to speed through the timing. 8. After a few minutes in heating mode, liquid line
For example, if interval is 90 min, the speed up will take temperature at defrost thermostat should drop below closing
(90/256)min x (60seconds /minute)= 21 seconds max. This set point of defrost thermostat of approximately 32_F.
could be shorter depending on how much time has elapsed Check resistance across defrost thermostat leads using
since the defrost thermostat closed. ohmmeter. Resistance of zero indicates defrost thermostat is
3. Remove the short immediately when the unit shifts into closed and operating properly.
defrost. Failure to remove the short immediately will result 9. Short between the speed--up terminals using a thermostat
in a very short forced defrost cycle (the 10 minute timer will screwdriver. This reduces the timing sequence to 1/256 of
be sped through in 2 seconds) original time. (See Table 3.)
4. When defrost begins, it will continue until the defrost Table 3—Defrost Control Speed--Up Timing Sequence
thermostat opens or 10 minutes has elapsed. MINIMUM MAXIMUM SPEED --- UP
PARAMETER
NOTE: The T1 terminal on the defrost board powers the defrost (MINUTES) (MINUTES) (NOMINAL)
30--- minute cycle 27 33 7 sec
timing function. This terminal must be energized before any
50--- minute cycle 45 55 12 sec
defrost function will occur. 90--- minute cycle 81 99 21 sec
If defrost thermostat is stuck closed: 10--- minute cycle 9 11 2 sec
Whether the unit is in heating or cooling mode, it will run a defrost 5--- minutes 4.5 5.5 1 sec
cycle for 10 minutes each time the compressor has been energized
for the selected time interval. The board will terminate
automatically after 10 minutes of defrost time regardless of defrost
! CAUTION
thermostat position. UNIT DAMAGE HAZARD
If defrost thermostat is stuck open: Failure to follow this caution may result in equipment
The unit will not defrost damage or improper operation.
NOTE: Unit will remain in defrost until defrost thermostat reopens Exercise extreme caution when shorting speed--up pins. If
at approximately 65_F coil temperature at liquid line or remainder pins are accidentally shorted to other terminals, damage to the
control board will occur.
of defrost cycle time.
5. Turn off power to outdoor unit and reconnect fan--motor 10. Unit is now operating in defrost mode. Check between C
lead to OF2 on control board after above forced--defrost and W2 using voltmeter. Reading on voltmeter should
cycle. indicate 24v. This step ensures defrost relay contacts have
If unit will not defrost: closed, energizing supplemental heat (W2) and reversing
valve solenoid (O).
1. Perform the speedup function as described above to test the
defrost function of the circuit board. 11. Unit should remain in defrost no longer than 10 minutes.
Actual time in defrost depends on how quickly speed--up
2. If the unit does not go into defrost after performing the
jumper is removed. If it takes 2 sec to remove speed--up
speed up, check for 24 volts on the T1 terminal. This
jumper after unit has switched to defrost, the unit will
terminal powers the defrost circuit, and must be energized
switch back to heat mode.
before any defrost function can occur. The T1 should be
energized once the Y terminal is energized and the pressure 12. After a few minutes, in defrost (cooling) operation, liquid
switches are closed. Ensure the T1 wire is connected at the line should be warm enough to have caused defrost
contactor, and that 24 volts is present on the T1 spade thermostat contacts to open. Check resistance across defrost
terminal. thermostat. Ohmmeter should read infinite resistance,
indicating defrost thermostat has opened at approximately
65_F.
13. Shut off unit power and reconnect fan lead.
16
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 3 to the ON position. Factory default is in
15. Replace control box cover. Restore power to unit. the OFF position. Enabling this feature eliminates occasional noise
If defrost thermostat does not check out following above items complaints associated with switching into and out of defrost.
or incorrect calibration is suspected, check for defective Five--Minute Compressor Delay
thermostat as follows:
This control features a 5--minute time delay to protect the
1. Follow items 1--5 above.
compressor from short cycling. The delay begins counting when
2. Route sensor or probe underneath coil (or other convenient the low voltage is interrupted, and at the end of heating or cooling
location) using thermocouple temperature measuring cycle.
device. Attach to liquid line near defrost thermostat. Insulate
for more accurate reading. SYSTEM FUNCTION AND
3. Turn on power to outdoor unit. SEQUENCE OF OPERATION
4. Restart unit in heating. On power--up (24 volts between R--C) the 5 minute cycle timer
5. Within a few minutes, liquid line temperature drops within a begins counting down. The compressor will not be energized until
range causing defrost thermostat contacts to close. this timer is elapsed.
Temperature range is from 33_F to 27_F. Notice Cooling
temperature at which ohmmeter reading goes from ∞ to zero
ohms. Thermostat contacts close at this point. On a call for cooling, thermostat makes R--O, R--Y, and R--G.
Circuit R--O energizes reversing valve switching it to cooling
6. Short between the speed--up terminals using a small slotted
position. Circuit R--Y sends low voltage through the safeties and
screwdriver.
energizes the T1 terminal on the circuit board. If the compressor
7. Unit changes over to defrost within 21 sec (depending on has been off for 5 minutes, or power has not been cycled for 5
timing cycle setting). Liquid line temperature rises to range minutes, the OF2 relay and T2 terminal will energize. This will
where defrost thermostat contacts open. Temperature range close the contactor, start the outdoor fan motor and compressor.
is from 60_F to 70_F. Resistance goes from zero to ∞ when
When the cycle is complete, R--Y is turned off and compressor and
contacts are open.
outdoor fan should stop. When using Carrier thermostats, the
8. If either opening or closing temperature does not fall within reversing valve remains energized in the cooling mode until the
above ranges or thermostat sticks in 1 position, replace thermostat is switched to heat, or the mode it turned off. The
thermostat to ensure proper defrost operation. 5--minute time guard begins counting. Compressor will not come
NOTE: With timing cycle set at 90 minutes, unit initiates defrost on again until this time delay expires. In the event of a power
within approximately 21 sec. When you hear the reversing valve interruption, the time guard will not allow another cycle for 5
changing position, remove screwdriver immediately. Otherwise, minutes.
control will terminate normal 10--minute defrost cycle in Heating
approximately 2 sec.
On a call for heating, thermostat makes R--Y, and R--G. Circuit
R--Y sends low voltage through the safeties and energizes the T1
T2 C C O
terminal on the circuit board. T1 energizes the defrost logic circuit.

OF1
If the compressor has been off for 5 minutes, or power has not been
OF2
cycled for 5 minutes, the OF2 relay and T2 terminal will energize.
DFT
O R W2 Y C
This will close the contactor, start the outdoor fan motor and
T1
compressor.
When the cycle is complete, R--Y is turned off and the compressor
Y
and outdoor fan should stop. The 5 minute time guard begins
P1
counting. Compressor will not come on again until this time delay
SPEEDUP
expires. In the event of a power interruption, the time guard will

60
30
INTERVAL TIMER OFF
J1
120
90
not allow another cycle for 5 minutes.

30
60
P3
Defrost Sequence
DFT
ON
SHIFT
QUIET
HK32EA003 The defrost control is a time/temperature control that has field

selectable settings of 30, 60, 90 and 120 minutes. These represent
Speedup
Pins
Quiet
Shift
Defrost interval
DIP switches the amount of time that must pass after closure of the defrost
A05378 thermostat before the defrost sequence begins.
Fig. 11 – HK32EA003 Defrost Control The defrost thermostat senses coil temperature throughout the
HK32EA003 Defrost Control heating cycle. When the coil temperature reaches the defrost
thermostat setting of approximately 32 degrees F, it will close,
The HK32EA003 defrost control is used in all 25HCA and 25HCB which energizes the DFT terminal and begins the defrost timing
Comfort Series heat pumps with Puron refrigerant. Its features sequence. When the DTF has been energized for the selected time,
include selectable defrost intervals of 30, 60, 90, & 120 minutes,
the defrost cycle begins. If the defrost thermostat opens before the
Quiet Shift, compressor time delay, deluxe defrost speed up timer expires, the timing sequence is reset.
capability. This section describes the sequence of operation and
trouble shooting methods for this control. Defrost cycle is terminated when defrost thermostat opens or
automatically after 10 minutes.
17
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). When Quiet Shift the need for a rain shield. For the correct position of fan blade
is off, only a short 30 second defrost cycle is observed. With Quiet assembly, the fan hub should be flush with the motor shaft.
Shift ON, the speed up sequence is one minute; 30 second Replacement motors and blades may vary slightly.
compressor off period followed by 30 seconds of defrost with
compressor operation. When returning to heating mode, the
compressor will turn off for an additional 30 seconds and the fan
! WARNING
for 40 seconds.
If the defrost thermostat is closed, a complete defrost cycle is
initiated. If the Quiet Shift switch is turned on, the compressor will Failure to follow this warning could result in personal injury
be turned off for two 30 second intervals as explained previously. or death.
Turn off all power before servicing or replacing fan motor. Be
sure unit main power switch is turned off.
Troubleshooting (HK32EA003)
If outdoor unit will not run:
The bearings are permanently lubricated, therefore, no oil ports are
1. Does the Y input have 24 volts from thermostat? If not, provided.
check thermostat or wire. If yes proceed to #2
For suspected electrical failures, check for loose or faulty electrical
2. The Y spade terminal should have 24 volts if Y input is connections, or defective fan motor capacitor. Fan motor is
energized. This output goes through the pressure switches equipped with thermal overload device in motor windings which
and back to the T1 input to energize the time delay and may open under adverse operating conditions. Allow time for
defrost timing circuit. If the contactor is not closed, the time motor to cool so device can reset. Further checking of motor can be
delay may still be active. Defeat time delay by shorting done with an ohmmeter. Set scale on R X 1 position, and check for
speed up pins for 1 second. Be sure not to short more than 1 continuity between 3 leads. Replace motors that show an open
second. circuit in any of the windings. Place 1 lead of ohmmeter on each
3. Once time delay has elapsed voltage on T2 should energize motor lead. At same time, place other ohmmeter lead on motor case
contactor. Check voltage on contactor coil. If no voltage is (ground). Replace any motor that shows resistance to ground,
present, check for opened pressure switch. arcing, burning, or overheating.
4. If voltage is present and contactor is open, contactor may be Compressor Plug
defective. Replace contactor The compressor electrical plug provides a quick--tight connection
5. If contactor is closed and unit will still not run, check to compressor terminals. The plug completely covers the
capacitor and compressor. compressor terminals and the mating female terminals are
If unit will not go into defrost: completely encapsulated in plug. Therefore, terminals are isolated
1. Perform speedup function as described above to test the from any moisture so corrosion and resultant pitted or discolored
defrost function of the circuit board. terminals are reduced. The plug is oriented to relief slot in terminal
box so cover cannot be secured if wires are not positioned in slot,
2. If the unit will go into defrost with the speed up, but will
assuring correct electrical connection at the compressor. The plug
not on its own, the defrost thermostat may not be
can be removed by simultaneously pulling while “rocking“ plug.
functioning properly. Perform the full defrost thermostat
However, these plugs can be used only on specific compressors.
and board troubleshooting the same as described for the
The configuration around the fusite terminals is outlined on the
HK32EA001 control. Other than the Quiet shift (if
terminal covers. The slot through which wires of plug are routed is
selected), and the speedup timing, the troubleshooting
oriented on the bottom and slightly to the left. The correct plug can
process is identical.
be connected easily to compressor terminals and plug wires can
3. If unit still will not run defrost, remove thermostat pigtail easily be routed through slot terminal cover.
harness from board and perform checks directly on input
It is strongly recommended to replace the compressor plug should
pins with jumper wires. The pigtail may have a bad
a compressor fail due to a suspected electrical failure. At a
connection or be mis--wired.
minimum, inspect plug for proper connection and good condition
on any compressor replacement.
Low--Voltage Terminals
The low--voltage terminal designations, and their description and
function, are used on all split--system condensers.
W—Energizes first--stage supplemental heat through defrost relay
(wht).
R—Energizes 24--v power from transformer (red).
Y—Energizes contactor for first--stage cooling or first--stage
heating for heat pumps (yel).
O—Energizes reversing valve on heat pumps (orn).
C—Common side of transformer (blk).
18
COPELAND SCROLL COMPRESSOR Compressor Failures
Compressor failures are classified in 2 broad failure categories;
mechanical and electrical. Both types are discussed below.
Scroll Gas Flow Mechanical Failures

A compressor is a mechanical pump driven by an electric motor
Compression in the scroll is
created by the interaction of contained in a welded or hermetic shell. In a mechanical failure,
an orbiting spiral and a
stationary spiral. Gas enters
motor or electrical circuit appears normal, but compressor does not
an outer opening as one of the
spirals orbits.
function normally.
1
! WARNING
or death.
Do not supply power to unit with compressor terminal box
2 3
cover removed.
The open passage is sealed off As the spiral continues to orbit,
as gas is drawn into the spiral. the gas is compressed into an
increasingly smaller pocket.
! WARNING
or death.
Exercise extreme caution when reading compressor currents
4 5
when high--voltage power is on. Correct any of the problems
By the time the gas arrives at
the center port, discharge
Actually, during operation, all
six gas passages are in various described below before installing and running a replacement
pressure has been reached. stages of compression at all
times, resulting in nearly con-
compressor.
tinuous suction and discharge.
Locked Rotor
In this type of failure, compressor motor and all starting
A90198 components are normal. When compressor attempts to start, it
Fig. 12 – Scroll Compressor Refrigerant Flow draws locked rotor current and cycles off on internal protection.
The compressors used in these products are specifically designed to Locked rotor current is measured by applying a clamp--on ammeter
operate with designated refrigerant and cannot be interchanged. around common (blk) lead of compressor. Current drawn when it
The compressor is an electrical (as well as mechanical) device. attempts to start is then measured. Locked rotor amp (LRA) value
Exercise extreme caution when working near compressors. Power is stamped on compressor nameplate.
should be shut off, if possible, for most troubleshooting techniques. If compressor draws locked rotor amps and all other external
Refrigerants present additional safety hazards. sources of problems have been eliminated, compressor must be
replaced. Because compressor is a sealed unit, it is impossible to
! CAUTION determine exact mechanical failure. However, complete system
should be checked for abnormalities such as incorrect refrigerant
charge, restrictions, insufficient airflow across indoor or outdoor
PERSONAL INJURY HAZARD coil, etc., which could be contributing to the failure.
Failure to follow this caution may result in personal injury. Runs, Does Not Pump
Wear safety glasses, protective clothing, and gloves when In this type of failure, compressor motor runs and turns
handling refrigerant. compressor, but compressor does not pump refrigerant. A
clamp--on ampmeter on common leg shows a very low current
The scroll compressor pumps refrigerant through the system by the draw, much lower than rated load amp (RLA) value stamped on
interaction of a stationary and an orbiting scroll. (See Fig. 12.) The compressor nameplate. Because no refrigerant is being pumped,
scroll compressor has no dynamic suction or discharge valves, and there is no return gas to cool compressor motor. It eventually
it is more tolerant of stresses caused by debris, liquid slugging, and overheats and shuts off on its internal protection.
flooded starts. The compressor is equipped with an internal
pressure relief port. The pressure relief port is a safety device,
designed to protect against extreme high pressure. The relief port
has an operating range between 550 to 625 psi differential pressure
for Puronr and 350 to 450 psi differential pressure for R--22.
Scrolls have a variety of shut down solutions, depending on model,
to prevent backward rotation and eliminate the need for cycle
protection.
19
Noisy Compressor 10. When a heat pump switches into and out of defrost, a
Noise may be caused by a variety of internal and external factors. ”swooshing” noise is expected due to the rapid pressure
Careful attention to the “type” of noise may help identify the change within the system. However customers sometimes
source. The following are some examples of abnormal conditions complain that the noise is excessive, or it is sometimes
that may create objectionable noise: accompanied by a ”groaning, or howling” noise. When
receiving these complaints, Quiet Shift (if available) may
1. A gurgling sound may indicate a liquid refrigerant
improve the noise, but will probably not eliminate it totally.
floodback during operation. This could be confirmed if
Check that the defrost thermostat or thermistor is operating
there is no compressor superheat. A compressor superheat
properly. Insulating the defrost sensing device may also
of “0” degrees would indicate liquid refrigerant returning to
help. If the howling or groaning noise is intermittent,
the compressor. Most common reasons for floodback are:
replacing the reversing valve may or may not help.
loss of evaporator blower, dirty coils, and improper airflow.
2. A rattling noise may indicate loose hardware. Inspect all
11. Rattling that occurs during a shift into or out of defrost on a
unit hardware including the compressor grommets.
heat pump could indicate a pressure differential issue. This
3. A straining (hard start) or vibration occurring at start up but is usually a brief occurrence (under 60 seconds) and can be
clears quickly after could indicate an off cycle refrigerant remedied by incorporating quiet shift, if available. This is a
migration issue. Refrigerant migration can occur when a device that shuts down the compressor during the defrost
compressor is off and refrigerant vapor transfers from other shift for 30 seconds allowing the pressures to equalize. It is
areas of the system, settles into the compressor as it is enabled by either a dip switch setting on the defrost board,
attracted to the oil, and then condenses into the oil. Upon or in the User Interface on communicating systems. Verify
start up, the compressor draws suction from within itself proper system charge as well.
first and lowers the boiling point of the refrigerant that is
entrained in the oil. This can cause the liquid refrigerant
and oil to boil into the compression area or liquid refrigerant
to wipe off oil films that are critical for proper lubrication.
Migration is worsened by greater temperature differentials
and/or extra refrigerant in the system. Prevention of
migration can be reduced by various options but some of
the more common remedies is to verify proper charge and
add a crankcase heater where this situation is suspected.
4. Operational vibration could indicate a charge issue. Verify
charge and ensure proper piping and structural penetration
insulation. Tubing that is too rigid to building rafters
without proper insulation could transfer noise throughout
the structure. On some occasions a sound dampener or
mass weight (RCD part no. 328209--751) placed on the
vibrating tubing has been known to reduce this noise.
A07124
Utilizing compressor split post grommets (see Fig. 13) may
also reduce this vibration if piping cannot be remedied. Fig. 13 – Split Post Grommet part number: KA75UG100
5. An operational high pitch frequency or “waa waa” sound
that appears to resonate through the suction line could
indicate a need to add more flex or muffling in the lines.
This has been occasional in scroll compressor applications
and is usually remedied by adding a field--fabricated suction
line loop (see Fig. 14). Reciprocating compressors may
have a noticeable discharge pulsation that could be
remedied with a field installed discharge muffler.
Recommend loop by continuous tubing with no more than
12 inches vertical and 6 inch horizontal loop.
6. An internal “thunking”, “thumping”, “grinding” or
“rattling” noise could indicate compressor internal failures
and may be verified by comparing the compressor
amperage to what the compressor should be drawing
according to a manufacturer’s performance data.
7. A whistling or squealing noise during operation may
indicate a partial blockage of the refrigerant charge.
8. A whistle on shut down could indicate a partial leak path as
refrigerant is equalizing from high to low side. On
occasion, an in--line discharge check valve has prevented Note: Long radius elbows recommended
this sound.
A07123
9. If a compressor hums but won’t start it could indicate either Fig. 14 – Suction Line Loop
a voltage or amperage issue. Verify adequate voltage and
operational start components if installed. If it is drawing
excessive amperage and voltage doesn’t appear to be the
problem it may be assumed a locked condition. Ensure
refrigerant has had ample time to equalize and boil out of
the compressor before condemning.
20
(EXAMPLE)
? TO DETERMINE INTERNAL CONNECTIONS OF SINGLE-
PHASE MOTORS (C,S,R) EXCEPT SHADED-POLE
?
POWER OFF! DEDUCTION:
? 1 3 (GREATEST RESISTANCE) RUN WINDING (R)
5.8Ω (OHM) START WINDING (S)
OHMMETER 2 3 (SMALLEST RESISTANCE) 2 IS COMMON (C)

0-10Ω SCALE 0.6Ω BY ELIMINATION
1 1
1 2 (REMAINING RESISTANCE) 2 IS COMMON,
2 5.2Ω
5.2Ω 5.8Ω THEREFORE, 1 IS
0.6Ω
2 START WINDING (S)
3 3
3 IS RUN WINDING (R)
A88344
Fig. 15 – Identifying Compressor Terminals
Electrical Failures Open Circuit
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 mechanical systems appear
! WARNING
normal. Compressor must be checked electrically for abnormalities. UNIT PERSONAL INJURY HAZARD
Before troubleshooting compressor motor, review this description Failure to follow this warning could result in personal injury.
of compressor motor terminal identification. Use caution when working near compressor terminals.
Single--Phase Motors Damaged terminals have the potential to cause personal injury.
To identify terminals C, S, and R:
1. Turn off all unit power.
Never put face or body directly in line with terminals.
2. Discharge run and start capacitors to prevent shock.
3. Remove all wires from motor terminals. To determine if any winding has a break in the internal wires and
4. Read resistance between all pairs of terminals using an current is unable to pass through, follow these steps:
ohmmeter on 0--10 ohm scale. 1. Be sure all power is off.
5. Determine 2 terminals that provide greatest resistance 2. Discharge all capacitors.
reading. 3. Remove wires from terminals C, S, and R.
Through elimination, remaining terminal must be common (C). 4. Check resistance from C--R, C--S, and R--S using an
Greatest resistance between common (C) and another terminal ohmmeter on 0--1000 ohm scale.
indicates the start winding because it has more turns. This terminal Because winding resistances are usually less than 10 ohms, each
is the start (S). The remaining terminal will be run winding (R). reading appears to be approximately 0 ohm. If resistance remains at
NOTE: If compressor is hot, allow time to cool and internal line 1000 ohms, an open or break exists and compressor should be
break to reset. There is an internal line break protector which must replaced.
be closed.
All compressors are equipped with internal motor protection. If
motor becomes hot for any reason, protector opens. Compressor
! CAUTION
should always be allowed to cool and protector to close before
UNIT DAMAGE HAZARD
troubleshooting. Always turn off all power to unit and disconnect
leads at compressor terminals before taking readings. Failure to follow this caution may result in equipment
damage or improper operation.
Most common motor failures are due to either an open, grounded,
or short circuit. When a compressor fails to start or run, 3 tests can Be sure internal line break overload is not temporarily open.
help determine the problem. First, all possible external causes
should be eliminated, such as overloads, improper voltage,
pressure equalization, defective capacitor(s), relays, wiring, etc.
Compressor has internal line break overload, so be certain it is
closed.
21
Ground Circuit REFRIGERATION SYSTEM
To determine if a wire has broken or come in direct contact with
shell, causing a direct short to ground, follow these steps: Refrigerant
1. Allow crankcase heaters to remain on for several hours
before checking motor to ensure windings are not saturated
with refrigerant.
! WARNING
2. Using an ohmmeter on R X 10,000 ohm scale or UNIT OPERATION AND SAFETY HAZARD
megohmmeter (follow manufacturer’s instructions). Failure to follow this warning could result in personal injury
3. Be sure all power is off. or equipment damage.
4. Discharge all capacitors. Puronr refrigerant which has higher pressures than R--22 and
other refrigerants. No other refrigerant may be used in this
5. Remove wires from terminals C, S, and R.
system. Gauge set, hoses, and recovery system must be
6. Place one meter probe on ground or on compressor shell. designed to handle Puronr. If you are unsure consult the
Make a good metal--to--metal contact. Place other probe on equipment manufacturer.
terminals C, S, and R in sequence.
7. Note meter scale. In an air conditioning and heat pump system, refrigerant transfers
heat from one replace to another. The condenser is the outdoor coil
8. If reading of 0 or low resistance is obtained, motor is
in the cooling mode and the evaporator is the indoor coil.
grounded. Replace compressor.
In a heat pump, the condenser is the indoor coil in the heating
Compressor resistance to ground should not be less than 1000
mode and the evaporator is the outdoor coil.
ohms per volt of operating voltage.
In the typical air conditioning mode, compressed hot gas leaves the
Example:
compressor and enters the condensing coil. As gas passes through
230 volts X 1000 ohms/volt = 230,000 ohms minimum. the condenser coil, it rejects heat and condenses into liquid. The
Short Circuit liquid leaves condensing unit through liquid line and enters
To determine if any wires within windings have broken through metering device at evaporator coil. As it passes through metering
their insulation and made contact with other wires, thereby shorting device, it becomes a gas--liquid mixture. As it passes through
all or part of the winding(s), be sure the following conditions are indoor coil, it absorbs heat and the refrigerant moves to the
met. compressor and is again compressed to hot gas, and cycle repeats.
1. Correct motor winding resistances must be known before Compressor Oil
testing, either from previous readings or from
manufacturer’s specifications.
2. Temperature of windings must be as specified, usually
! CAUTION
about 70_F.
UNIT DAMAGE HAZARD
3. Resistance measuring instrument must have an accuracy
within ± 5--10 percent. This requires an accurate ohmmeter Failure to follow this caution may result in equipment
such as a Wheatstone bridge or null balance--type damage or improper operation.
instrument. The compressor in a Puronr system uses a polyol ester
4. Motor must be dry or free from direct contact with liquid (POE) oil. This oil is extremely hygroscopic, meaning it
refrigerant. absorbs water readily. POE oils can absorb 15 times as much
water as other oils designed for HCFC and CFC refrigerants.
Make This Critical Test Take all necessary precautions to avoid exposure of the oil to
(Not advisable unless above conditions are met) the atmosphere. (See Table 4.)
1. Be sure all power is off.
2. Discharge all capacitors.
3. Remove wires from terminals C, S, and R.
4. Place instrument probes together and determine probe and
lead wire resistance.
5. 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.
22
Table 4—Oil Charging
REFRIGERANT COMPRESSOR MODEL RECHARGE (FL OZ) OIL TYPE
COPELAND
PURON ZP16--- 26 38 3MA POE (32 cSt)
PURON ZP32--- 41 42 3MA POE (32 cSt)
PURON P54 53 3MA POE (32 cSt)
PURON--- 2 STAGE ZPS20, ZPS30, ZPS40 34 3MAF--- POE
PURON--- 2 STAGE ZPS49, ZPS51 52 3MAF--- POE
BRISTOL
PURON--- 2 STAGE T81J195 27 MOBIL 32BC
PURON--- 2 STAGE T81J285, 384 37 MOBIL 32BC
PURON--- 2 STAGE T81J515 62 MOBIL 32BC
SCROLL TECHNOLOGIES
PURON XG*32--- 38 36 HATCO POE 32--- ST
PURON XN*41--- 56 53 HATCO POE 32--- ST
COPELAND
R22 ZR16--- 32 19 3GS--- 32YMO (blended white oil)
R22 ZR38--- 34 3GS--- 32YMO (blended white oil)
SCROLL TECHNOLOGIES
R22 XC*38--- 42 36 Zerol 150--- T
R22 XC*43--- 47 45 Zerol 150--- T
R22 XR*48--- 60 53 Zerol 150--- T
Servicing Systems on Roofs With Synthetic Brazing

Materials This section on brazing is not intended to teach a technician how to
POE (polyol ester) compressor lubricants are known to cause long braze. There are books and classes which teach and refine brazing
term damage to some synthetic roofing materials. Exposure, even if techniques. The basic points below are listed only as a reminder.
immediately cleaned up, may cause embrittlement (leading to Definition: The joining and sealing of metals using a nonferrous
cracking) to occur in one year or more. When performing any metal having a melting point over 800_F/426.6_C.
service which may risk exposure of compressor oil to the roof, take Flux: A cleaning solution applied to tubing or wire before it is
appropriate precautions to protect roofing. Procedures which risk brazed. Flux improves the strength of the brazed connection.
oil leakage include but are not limited to compressor replacement, When brazing is required in the refrigeration system, certain basics
repairing refrigerants leaks, replacing refrigerant components such should be remembered. The following are a few of the basic rules.
as filter drier, pressure switch, metering device, coil, accumulator,
or reversing valve. 1. Clean joints make the best joints. To clean:
Synthetic Roof Precautionary Procedure ⎯ Remove all oxidation from surfaces to a shiny
finish before brazing.
1. Cover extended roof working area with an impermeable
polyethylene (plastic) drop cloth or tarp. Cover an ⎯ Remove all flux residue with brush and water while
approximate 10 x 10 ft area. material is still hot.
2. Cover area in front of the unit service panel with a terry 2. Silver brazing alloy is used on copper--to--brass,
cloth shop towel to absorb lubricant spills and prevent copper--to--steel, or copper--to--copper. Flux is required
run--offs, and protect drop cloth from tears caused by tools when using silver brazing alloy. Do not use low temperature
or components. solder.
3. Place terry cloth shop towel inside unit immediately under 3. Fluxes should be used carefully. Avoid excessive
component(s) to be serviced and prevent lubricant run--offs application and do not allow fluxes to enter into the system.
through the louvered openings in the base pan. 4. Brazing temperature of copper is proper when it is heated to
4. Perform required service. a minimum temperature of 800_F and it is a dull red color
5. Remove and dispose of any oil contaminated material per in appearance.
local codes.
23
Service Valves and Pumpdown
! CAUTION
! WARNING 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 Wear safety glasses, protective clothing, and gloves when
or equipment damage. handling refrigerant.
Never attempt to make repairs to existing service valves. Unit
Pumpdown Procedure
operates under high pressure. Damaged seats and o--rings
should not be replaced. Replacement of entire service valve is Service valves provide a convenient shutoff valve useful for certain
required. Service valve must be replaced by properly trained refrigeration--system repairs. System may be pumped down to
service technician. make repairs on low side without losing complete refrigerant
charge.
Service valves provide a means for holding original factory charge 1. Attach pressure gauge to suction service--valve gauge port.
in outdoor unit prior to hookup to indoor coil. They also contain 2. Front seat liquid--line valve.
gauge ports for measuring system pressures and provide shutoff 3. Start unit in cooling mode. Run until suction pressure
convenience for certain types of repairs. (See Fig. 16 and Fig. 17.) reaches 5 psig (35kPa). Do not allow compressor to pump
Two types of service valves are used in outdoor residential to a vacuum.
equipment. The first type is a front--seating valve, which has a 4. Shut unit off. Front seat suction valve.
service port that contains a Schrader fitting. The service port is
always pressurized after the valve is moved off the front--seat STAINLESS
position. STEEL
STEM
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 (will no longer turn counter
clockwise), the service port is not pressurized. To pressurize the
service port, this valve must be moved off the back--seating SERVICE
PORT
position (turned clockwise slightly). The gage port in this valve ENTRANCE
does not contain a Schrader fitting. Both types of service valves are
designed for sweat connection to the field tubing.
BACK
The service valves in the outdoor unit come from the factory SEAT
POSITION
front--seated. This means that the refrigerant charge is isolated from FIELD SIDE
the line--set connection ports. All heat pumps are shipped with an
adapter stub tube. This tube must be installed on the liquid service
valve. After connecting the stub tube to the liquid service valve of FRONT
SEAT
a heat pump, the valves are ready for brazing. The interconnecting POSITION
tubing (line set) can be brazed to the service valves using industry
accepted methods and materials. Consult local codes.
Before brazing the line set to the valves, the belled ends of the
FORGED BACK SEATING VALVE
sweat connections on the service valves must be cleaned so that no
brass plating remains on either the inside or outside of the bell
A91435
joint. To prevent damage to the valve and/or cap “O” ring, use a
Fig. 16 – Suction Service Valve (Back Seating)
wet cloth or other acceptable heat--sinking material on the valve
Used in Preferred and Infinity ACs and HPs.
before brazing. To prevent damage to the unit, use a metal barrier
FIELD
between brazing area and unit. SIDE
After the brazing operation and the refrigerant tubing and STEM
evaporator coil have been evacuated, the valve stem can be turned
counterclockwise until back--seats, which releases refrigerant into
tubing and evaporator coil. The system can now be operated. SERVICE PORT
W/SCHRADER CORE
Back--seating service valves must be back--seated (turned
counterclockwise until seated) before the service--port caps can be
removed and hoses of gauge manifold connected. In this position, SEAT
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 BAR STOCK FRONT SEATING VALVE
tightened to attain a metal--to--metal seal. If accessory pressure

switches are used, the service valve must be cracked. Then, the A91447
knife--set stem cap becomes the primary seal. Fig. 17 – Suction Service Valve (Front Seating)
The service valve cannot be field repaired; therefore, only a Used in Base and Comfort ACs and HPs
complete valve or valve stem and service--port caps are available NOTE: All outdoor unit coils will hold only factory--supplied
for replacement. amount of refrigerant. Excess refrigerant, such as in long--line
If the service valve is to be replaced, a metal barrier must be applications, may cause unit to relieve pressure through internal
inserted between the valve and the unit to prevent damaging the pressure--relief valve (indicated by sudden rise of suction pressure)
unit exterior from the heat of the brazing operations. before suction pressure reaches 5 psig (35kPa). If this occurs, shut
unit off immediately, front seat suction valve, and recover
remaining pressure.
24
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. Flare connections
are used in R--22 systems.
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 A05226
AccuRaterr. Fig. 18 – Front Seating Service Valve with Chatleff
4. Pull retainer out of body, being careful not to scratch flare Connection Used in Base, Comfort, and 4--Sided Performance
sealing surface. If retainer does not pull out easily, carefully and Infinity Puron Heat Pumps.
use locking pliers to remove it.
5. Slide piston and piston ring out by inserting a small soft
wire with small kinks through metering hole. Do not TEFLONr SEAL
damage metering hole, sealing surface around piston cones,
or fluted portion of piston. PISTON
6. Clean piston refrigerant metering hole.
7. Install a new retainer O--ring, retainer assembly, or Teflon
washer before reassembling AccuRaterr.
SWEAT / FLARE
PISTON
ADAPTER
BODY
A05226
Fig. 19 – Back Seating Liquid Service Valve
Used in 3--Sided Performance and Infinity Heat Pumps
(all Puron)
PISTON BODY
PISTON
PISTON
RETAINER
SWEAT/FLARE ADAPTER
A01019
Fig. 20 – AccuRaterr Components
(used in R--22 Heat Pumps)
25
Reversing Valve If valve is defective:
In heat pumps, changeover between heating and cooling modes is 1. Shut off all power to unit and remove charge from system.
accomplished with a valve that reverses flow of refrigerant in 2. Remove solenoid coil from valve body. Remove valve by
system. This reversing valve device is easy to troubleshoot and cutting it from system with tubing cutter. Repair person
replace. The reversing valve solenoid can be checked with power should cut in such a way that stubs can be easily re--brazed
off with an ohmmeter. Check for continuity and shorting to back into system. Do not use hacksaw. This introduces
ground. With control circuit (24v) power on, check for correct chips into system that cause failure. After defective valve is
voltage at solenoid coil. Check for overheated solenoid. removed, wrap it in wet rag and carefully unbraze stubs.
With unit operating, other items can be checked, such as frost or Save stubs for future use. Because defective valve is not
condensate water on refrigerant lines. overheated, it can be analyzed for cause of failure when it is
The sound made by a reversing valve as it begins or ends defrost is returned.
a “whooshing” sound, as the valve reverses and pressures in system 3. Braze new valve onto used stubs. Keep stubs oriented
equalize. An experienced service technician detects this sound and correctly. Scratch corresponding matching marks on old
uses it as a valuable troubleshooting tool. valve and stubs and on new valve body to aid in lining up
Using a remote measuring device, check inlet and outlet line new valve properly. When brazing stubs into valve, protect
temperatures. DO NOT touch lines. If reversing valve is operating valve body with wet rag to prevent overheating.
normally, inlet and outlet temperatures on appropriate lines should 4. Use slip couplings to install new valve with stubs back into
be close to each other. Any difference would be due to heat loss or system. Even if stubs are long, wrap valve with a wet rag to
gain across valve body. Temperatures are best checked with a prevent overheating.
remote reading electronic--type thermometer with multiple probes. 5. After valve is brazed in, check for leaks. Evacuate and
Route thermocouple leads to inside of coil area through service charge system. Operate system in both modes several times
valve mounting plate area underneath coil. Fig. 21 and Fig. 22 to be sure valve functions properly.
show test points (TP) on reversing valve for recording
temperatures. Insulate points for more accurate reading.
TO
FROM ACCUMULATOR TO INDOOR COIL
OUTDOOR VIA SERVICE VALVE
FROM INDOOR COIL VIA
TO OUTDOOR SERVICE VALVE ON COIL ON OUTDOOR COIL
COIL OUTDOOR COIL
TO
ACCUMULATOR INSULATE
FOR
TP--4 TP--3 ACCURATE TP--2
READING
TP--4 TP--3 TP--2
INSULATE FOR
ACCURATE TP--1
READING
TP--1
FROM COMPRESSOR
DISCHARGE LINE
FROM COMPRESSOR
DISCHARGE LINE
ELECTRONIC
THERMOMETER
A88342 A88341
Fig. 21 – Reversing Valve Fig. 22 – Reversing Valve
(Cooling Mode or Defrost Mode, Solenoid Energized) (Heating Mode, Solenoid De--Energized)
26
Liquid Line Filter Drier Install Liquid--line Filter Drier Indoor -- HP
Filter driers are specifically designed for R--22 or Puronr Refer to Fig. 24 and install filter drier as follows:
refrigerant. Only operate with the appropriate drier using factory 1. Braze 5 in. liquid tube to the indoor coil.
authorized components. 2. Wrap filter drier with damp cloth.
It is recommended that the liquid line drier be installed at the 3. Braze filter drier to 5 in. long liquid tube from step 1.
indoor unit. Placing the drier near the TXV allows additional
protection to the TXV as the liquid line drier also acts as a strainer. 4. Connect and braze liquid refrigerant tube to the filter drier.
Suction Line Filter Drier
Install Liquid--line Filter Drier Indoor -- AC The suction line drier is specifically designed to operate with
Puronr, use only factory authorized components. Suction line filter
! CAUTION drier is used in cases where acid might occur, such as burnout. Heat
pump units must have the drier installed between the compressor
and accumulator only. Remove after 10 hours of operation. Never
UNIT DAMAGE HAZARD leave suction line filter drier in a system longer than 72 hours
Failure to follow this caution may result in equipment damage (actual time).
or improper operation.
To avoid performance loss and compressor failure, installation
of filter drier in liquid line is required.
! CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage
or improper operation.
To avoid filter drier damage while brazing, filter drier must be
wrapped in a heat--sinking material such as a wet cloth.
Refer to Fig. 23 and install filter drier as follows:

1. Braze 5--in. liquid tube to the indoor coil.
2. Wrap filter drier with damp cloth.
3. Braze filter drier to above 5” liquid tube. Flow arrow must
point towards indoor coil.
4. Connect and braze liquid refrigerant tube to the filter drier.
A05178 A05227
Fig. 23 – Liquid Line Filter Drier -- AC Fig. 24 – Liquid Line Filter Drier -- HP
27
Accumulator
The accumulator is specifically designed to operate with Puronr ! CAUTION
or R22 respectfully; use only factory--authorized components.
Under some light load conditions on indoor coils, liquid refrigerant PERSONAL INJURY HAZARD
is present in suction gas returning to compressor. The accumulator Failure to follow this caution may result in personal injury.
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
handling refrigerant.
refrigerant in its gaseous state, introduction of liquid into it could
cause severe damage or total failure of compressor.
4. Remove accumulator from system with tubing cutter.
The accumulator is a passive device which seldom needs replacing.
Occasionally its internal oil return orifice or bleed hole may 5. Tape ends of open tubing.
become plugged. Some oil is contained in refrigerant returning to 6. Scratch matching marks on tubing studs and old
compressor. It cannot boil off in accumulator with liquid accumulator. Scratch matching marks on new accumulator.
refrigerant. The bleed hole allows a small amount of oil and Unbraze stubs from old accumulator and braze into new
refrigerant to enter the return line where velocity of refrigerant accumulator.
returns it to compressor. If bleed hole plugs, oil is trapped in 7. Thoroughly rinse any flux residue from joints and paint
accumulator, and compressor will eventually fail from lack of with corrosion--resistant coating such as zinc--rich paint.
lubrication. If bleed hole is plugged, accumulator must be changed. 8. Install factory authorized accumulator into system with
The accumulator has a fusible element located in the bottom end copper slip couplings.
bell. (See Fig. 25.) This fusible element will melt at 430_F//221_C
9. Evacuate and charge system.
and vent the refrigerant if this temperature is reached either internal
or external to the system. If fuse melts, the accumulator must be Pour and measure oil quantity (if any) from old accumulator. If
replaced. more than 20 percent of oil charge is trapped in accumulator, add
new POE oil to compressor to make up for this loss. (See Table 4.)
To change accumulator:
1. Shut off all power to unit.
2. Recover all refrigerant from system.
3. Break vacuum with dry nitrogen. Do not exceed 5 psig.
NOTE: Coil may be removed for access to accumulator. Refer to
appropriate sections of Service Manual for instructions.
430° FUSE
ELEMENT
A88410
Fig. 25 – Accumulator
28
Thermostatic Expansion Valve (TXV) IMPORTANT: The TXV should be mounted as close to the
All fan coils and furnace coils will have a factory installed indoor coil as possible and in a vertical, upright position. Avoid
thermostatic expansion valve (TXV). The TXV will be a bi--flow, mounting the inlet tube vertically down. The valve is more
hard--shutoff with an external equalizer and a balance port pin. A susceptible to malfunction due to debris if inlet tube is facing
hard shut--off TXV does not have a bleed port. Therefore, down. A factory--approved filter drier must be installed in the
minimal equalization takes place after shutdown. TXVs are liquid line at the indoor unit.
specifically designed to operate with Puronr or R--22 refrigerant, Installing TXV in Place of Piston in a Rated Indoor Coil
use only factory authorized TXV’s. Do not interchange Puron (pre--2006)
and R--22 TXVs. 1. Pump system down to 2 psig and recover refrigerant.
TXV Operation 2. Remove hex nut from piston body. Use backup wrench on
The TXV is a metering device that is used in air conditioning and fan coils.
heat pump systems to adjust to changing load conditions by 3. Remove and discard factory--installed piston. Be sure Teflon
maintaining a preset superheat temperature at the outlet of the seal is in place.
evaporator coil. The volume of refrigerant metered through the
4. Reinstall hex nut. Finger tighten nut plus 1/2 turn.
valve seat is dependent upon the following:
NOTE: If the piston is not removed from the body, TXV will not
1. Superheat temperature is sensed by cap tube sensing bulb
on suction tube at outlet of evaporator coil. This function properly.
temperature is converted into pressure by refrigerant in the
bulb pushing downward on the diaphragm which opens the
valve via the pushrods.
! CAUTION
2. The suction pressure at the outlet of the evaporator coil is
EQUIPMENT DAMAGE HAZARD
transferred via the external equalizer tube to the underside
of the diaphragm. This is needed to account for the indoor Failure to follow this caution may result in equipment
coil pressure drop. Residential coils typically have a high damage or improper operation.
pressure drop, which requires this valve feature. Use a brazing shield and wrap TXV with wet cloth or
3. The pin is spring loaded, which exerts pressure on the use heat sink material
underside of the diaphragm. Therefore, the bulb pressure
works against the spring pressure and evaporator suction 5. Install TXV on indoor coil liquid line. Sweat swivel adapter
pressure to open the valve. to inlet of indoor coil and attach to TXV outlet. Use backup
If the load increases, the temperature increases at the bulb, wrench to avoid damage to tubing or valve. Sweat inlet of
which increases the pressure on the top side of the TXV, marked “IN” to liquid line. Avoid excessive heat
diaphragm. This opens the valve and increases the flow of which could damage valve.
refrigerant. The increased refrigerant flow causes the 6. Install vapor elbow with equalizer adapter to suction tube of
leaving evaporator temperature to decrease. This lowers the line set and suction connection to indoor coil. Adapter has a
pressure on the diaphragm and closes the pin. The 1/4--in. male connector for attaching equalizer tube.
refrigerant flow is effectively stabilized to the load demand 7. Connect equalizer tube of TXV to 1/4--in. equalizer fitting
with negligible change in superheat. on vapor line adapter.
Install TXV 8. Attach TXV bulb to horizontal section of suction line using
The thermostatic expansion valve is specifically designed to clamps provided. Insulate bulb with field--supplied
operate with a refrigerant type. Do not use an R--22 TXV on a insulation tape. See Fig. 26 for correct positioning of
Puron system, and do not use a Puron valve on an R--22 system. sensing bulb.
Refer to Product Data Sheet for the appropriate TXV kit number. 9. Proceed with remainder of unit installation.
CAUTION
10 O’CLOCK
! 2 O’CLOCK
SENSING BULB
UNIT OPERATION HAZARD

Failure to follow this caution may result in equipment STRAP

Al indoor coil units must be installed with a hard shut
off PuronR TXV metering device. SUCTION TUBE
A08083
Fig. 26 – Position of Sensing Bulb
29
Replacing TXV on an Indoor Coil (pre--2006) clamps (nylon or copper). See Fig. 26 for correct
1. Pump system down to 2 psig and recover refrigerant. positioning of sensing bulb.
2. Remove coil access panel and fitting panel from front of 11. Route equalizer tube through suction connection opening
cabinet. (large hole) in fitting panel and install fitting panel in place.
3. Remove TXV support clamp using a 5/16--in. nut driver. 12. Sweat inlet of TXV, marked “IN” to liquid line. Avoid
Save the clamp. excessive heat which could damage valve.
4. Remove R--22 TXV using a backup wrench on flare 13. Proceed with remainder of unit installation.
connections to prevent damage to tubing.
5. Using wire cutters, cut equalizer tube off flush with vapor
tube inside cabinet.
MAKE PIPING CONNECTIONS
6. Remove bulb from vapor tube inside cabinet.
7. Braze equalizer stub--tube closed. Use protective barrier as
! WARNING
necessary to prevent damage to drain pan. PERSONAL INJURY AND ENVIRONMENTAL
IMPORTANT: Route the equalizer tube of TXV through HAZARD
suction line connection opening in fitting panel prior to Failure to follow this warning could result in personal injury
replacing fitting panel around tubing. or death.
8. Install TXV with 3/8--in. copper tubing through small hole Relieve pressure and recover all refrigerant before system
in service panel. Use wrench and backup wrench, to avoid repair or final unit disposal.
damage to tubing or valve, to attach TXV to distributor.
Use all service ports and open all flow--control devices,
9. Reinstall TXV support clamp (removed in item 3). including solenoid valves.
10. Attach TXV bulb to vapor tube inside cabinet, in same
location as original was when removed, using supplied bulb
clamps (nylon or copper). See Fig. 26 for correct
positioning of sensing bulb.
! CAUTION
11. Route equalizer tube through suction connection opening UNIT DAMAGE HAZARD
(large hole) in fitting panel and install fitting panel in place.
Failure to follow this caution may result in equipment damage
12. Sweat inlet of TXV, marked “IN” to liquid line. Avoid or improper operation.
excessive heat which could damage valve.
Do not leave system open to atmosphere any longer than
13. Install vapor elbow with equalizer adapter to vapor line of minimum required for installation. POE oil in compressor is
line set and vapor connection to indoor coil. Adapter has a extremely susceptible to moisture absorption. Always keep
1/4--in. male connector for attaching equalizer tube. ends of tubing sealed during installation.
14. Connect equalizer tube of TXV to 1/4--in. equalizer fitting
on vapor line adapter. Use backup wrench to prevent
damage to equalizer fitting. ! CAUTION
15. Proceed with remainder of unit installation.
UNIT DAMAGE HAZARD
Replacing TXV on Indoor Coil (post--2006)
Failure to follow this caution may result in equipment
1. Pump system down to 2 psig and recover refrigerant. damage or improper operation.
2. Remove coil access panel and fitting panel from front of If ANY refrigerant tubing is buried, provide a 6 in. vertical
cabinet. rise at service valve. Refrigerant tubing lengths up to 36 in.
may be buried without further special consideration. Do not
3. Remove TXV support clamp using a 5/16--in. nut driver.
bury lines longer than 36 in.
Save the clamp (N coils only).
4. Remove TXV using a backup wrench on connections to
prevent damage to tubing.
5. Remove equalizer tube from suction line of coil.
Note: Some coils may have a mechanical connection. If
coil has a braze connection, use file or tubing cutter to cut COIL
brazed equalizer line approximately 2 inches above suction SENSING
BULB
tube.
6. Remove bulb from vapor tube inside cabinet. EQUALIZER
TUBE
7. Install the new TXV using a wrench and backup wrench to
avoid damage to tubing or valve to attach TXV to
distributor.
8. Reinstall TXV support clamp (removed in item 3). (N coils
THERMOSTATIC
only.) EXPANSION
VALVE
9. Attach equalizer tube to suction line. If coil has mechanical
connection, then use wrench and back up wrench to attach. A91277
If coil has brazed connection, use file or tubing cutters to Fig. 27 – Typical TXV Installation
remove mechanical flare nut from equalizer line. Then use
coupling to braze the equalizer line to stub (previous
equalizer line) in suction line.
10. Attach TXV bulb to vapor tube inside cabinet, in same
location as original was when removed, using supplied bulb
30
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 LEAK
than refrigerants. Nitrogen cannot, however, be detected by an DETECTOR
electronic leak detector. (See Fig. 28.) SOLUTION
BEEP
BEEP
A95423
Fig. 29 – Bubble Leak Detection
You may use an electronic leak detector designed for specific
refrigerant to check for leaks. (See Fig. 28.) This unquestionably is
the most efficient and easiest method for checking leaks. There are
various types of electronic leak detectors. Check with manufacturer
of equipment for suitability. Generally speaking, they are portable,
lightweight, and consist of a box with several switches and a probe
or sniffer. Detector is turned on and probe is passed around all
fittings and connections in system. Leak is detected by either the
A95422 movement of a pointer on detector dial, a buzzing sound, or a light.
Fig. 28 – Electronic Leak Detection In all instances when a leak is found, system charge must be
recovered and leak repaired before final charging and operation.
! WARNING After leak testing or leak is repaired, replace liquid line filter drier,
evacuate system, and recharge with correct refrigerant quantity.
PERSONAL INJURY AND UNIT DAMAGE Coil Removal
HAZARD Coils are easy to remove if required for compressor removal, or to
Failure to follow this warning could result in personal replace coil.
injury or death. 1. Shut off all power to unit.
Due to the high pressure of nitrogen, it should never be 2. Recover refrigerant from system through service valves.
used without a pressure regulator on the tank. 3. Break vacuum with nitrogen.
Assuming that a system is pressurized with either all refrigerant or 4. Remove top cover. (See Remove Top Cover in Cabinet
a mixture of nitrogen and refrigerant, leaks in the system can be section of the manual.)
found with an electronic leak detector that is capable of detecting 5. Remove screws in base pan to coil grille.
specific refrigerants. 6. Remove coil grille from unit.
If system has been operating for some time, first check for a leak 7. Remove screws on corner post holding coil tube sheet.
visually. Since refrigerant carries a small quantity of oil, traces of
oil at any joint or connection is an indication that refrigerant is
leaking at that point.
! WARNING
A simple and inexpensive method of testing for leaks is to use soap FIRE HAZARD
bubbles. (See Fig. 29.) Any solution of water and soap may be
used. Soap solution is applied to all joints and connections in Failure to follow this warning could result in personal
system. A small pinhole leak is located by tracing bubbles in soap injury or equipment damage.
solution around leak. If the leak is very small, several minutes may Cut tubing to reduce possibility of personal injury and fire.
pass before a bubble will form. Popular commercial leak detection
solutions give better, longer--lasting bubbles and more accurate 8. Use midget tubing cutter to cut liquid and vapor lines at
results than plain soapy water. The bubble solution must be both sides of coil. Cut in convenient location for easy
removed from the tubing and fittings after checking for leaks as reassembly with copper slip couplings.
some solutions may corrode the metal. 9. Lift coil vertically from basepan and carefully place aside.
10. Reverse procedure to reinstall coil.
11. Replace filter drier, evacuate system, recharge, and check
for normal systems operation.
31
Compressor Removal and Replacement System Clean--Up After Burnout
Once it is determined that compressor has failed and the reason Some compressor electrical failures can cause motor to burn. When
established, compressor must be replaced. this occurs, by--products of burn, which include sludge, carbon,
and acids, contaminate system. Test the oil for acidity using POE
! CAUTION oil acid test to determine burnout severity. 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
PERSONAL INJURY HAZARD severe.
Failure to follow this caution may result in personal injury. In mild burnout, there is little or no detectable odor. Compressor
Turn off all power to unit before proceeding. Wear safety oil is clear or slightly discolored. An acid test of compressor oil
glasses, protective clothing, and gloves when handling will be negative. This type of failure is treated the same as
refrigerant. Acids formed as a result of motor burnout can mechanical failure. Liquid--line strainer should be removed and
cause burns. liquid--line filter drier replaced.
In a severe burnout, there is a strong, pungent, rotten egg odor.
Compressor oil is very dark. Evidence of burning may be present
! CAUTION in tubing connected to compressor. An acid test of compressor oil
will be positive. Follow these additional steps:
PERSONAL INJURY HAZARD 1. TXV must be cleaned or replaced.
Failure to follow this caution may result in personal injury. 2. Drain any trapped oil from accumulator if used.
3. Remove and discard liquid--line strainer and filter drier.
handling refrigerant and when using brazing torch.. 4. After system is reassembled, install liquid and suction--line
Puronr filter driers.
1. Shut off all power to unit. NOTE: On heat pumps, install suction line drier between
2. Remove and recover all refrigerant from system until compressor and accumulator.
pressure gauges read 0 psi. Use all service ports. Never open 5. Operate system for 10 hr. Monitor pressure drop across
a system under a vacuum to atmosphere. Break vacuum drier. If pressure drop exceeds 3 psig replace suction--line
with dry nitrogen holding charge first. Do not exceed 5 and liquid--line filter driers. Be sure to purge system with
psig. dry nitrogen when replacing filter driers. If suction line
3. Disconnect electrical leads from compressor. Disconnect or driers must be replaced, retest pressure drop after additional
remove crankcase heater and remove compressor 10 hours (run time). Continue to monitor pressure drop
hold--down bolts. across suction line filter drier. After 10 hr of run time,
4. Cut compressor from system with tubing cutter. Do not use remove suction--line filter drier and replace liquid--line filter
brazing torch for compressor removal. Oil vapor may ignite drier. Never leave suction--line filter drier in system longer
when compressor is disconnected. than 72 hr (run time).
5. Scratch matching marks on stubs in old compressor. Make 6. Charge system. (See unit information plate.)
corresponding marks on replacement compressor.
6. Use torch to remove stubs from old compressor and to
reinstall them in replacement compressor.
! CAUTION
7. Use copper couplings to tie compressor back into system. UNIT DAMAGE HAZARD
8. Replace filter drier, evacuate system, recharge, and check Failure to follow this caution may result in equipment
for normal system operation. damage or improper operation.
Only suction line filter driers should be used for refrigerant
! CAUTION and oil clean up. Use of non--approved products could limit
system life and void unit warranty.
UNIT DAMAGE HAZARD
Do not leave system open to atmosphere. Compressor oil is
highly susceptible to moisture absorption.
32
Evacuation CHECK CHARGE
Proper evacuation of the system will remove non--condensibles (See Charging Tables 11 & 13)
and assure a tight, dry system before charging. The 2 methods used
Factory charge amount and desired subcooling are shown on unit
to evacuate a system are the deep vacuum method and the triple
rating plate. Charging method is shown on information plate inside
evacuation method.
unit. To properly check or adjust charge, conditions must be
Deep Vacuum Method favorable for subcooling charging. Favorable conditions exist
The deep vacuum method requires a vacuum pump capable of when the outdoor temperature is between 70_F and 100_F
pulling a vacuum of 500 microns and a vacuum gauge capable of (21.11_C and 37.78_C), and the indoor temperature is between
accurately measuring this vacuum depth. The deep vacuum method 70_F and 80_F (21.11_C and 26.67_C). Follow the procedure
is the most positive way of assuring a system is free of air and below:
moisture. (See Fig. 30.) Unit is factory charged for 15ft (4.57 m) of lineset. Adjust charge
5000 by adding or removing 0.6 oz/ft of 3/8 liquid line above or below
15ft (4.57 m) respectively.
4500
For standard refrigerant line lengths (80 ft/24.38 m or less), allow
4000 system to operate in cooling mode at least 15 minutes. If conditions
LEAK IN
3500 SYSTEM are favorable, check system charge by subcooling method. If any
MICRONS
3000 adjustment is necessary, adjust charge slowly and allow system to

2500 operate for 15 minutes to stabilize before declaring a properly
charged system.
2000
VACUUM TIGHT If the indoor temperature is above 80_F (26.67_C), and the
1500 outdoor temperature is in the favorable range, adjust system charge
TOO WET
1000 by weight based on line length and allow the indoor temperature to
TIGHT drop to 80_F (26.67_C) before attempting to check system charge
500 DRY SYSTEM
by subcooling method as described above.
0 1 2 3 4 5 6 7 If the indoor temperature is below 70_F (21.11_C), or the outdoor
MINUTES temperature is not in the favorable range, adjust charge for line set
length above or below 15ft (4.57 m) only. Charge level should then
A95424 be appropriate for the system to achieve rated capacity. The charge
Fig. 30 – Deep Vacuum Graph level could then be checked at another time when the both indoor
Triple Evacuation Method and outdoor temperatures are in a more favorable range.
The triple evacuation method should be used when vacuum pump NOTE: If line length is beyond 80 ft (24.38 m) or greater than 20
is only capable of pumping down to 28 in. of mercury vacuum and ft (6.10 m) vertical separation, See Long Line Guideline for
system does not contain any liquid water. Refer to Fig. 31 and special charging requirements.
proceed as follows:
1. Pump system down to 28 in. of mercury and allow pump to
continue operating for an additional 15 minutes.
2. Close service valves and shut off vacuum pump.
3. Connect a nitrogen cylinder and regulator to system and
open until system pressure is 2 psig.
4. Close service valve and allow system to stand for 1 hr.
During this time, dry nitrogen will be able to diffuse
throughout the system absorbing moisture.
5. Repeat this procedure as indicated in Fig. 31. System will
then be free of any contaminants and water vapor.
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
CHECK FOR TIGHT, DRY SYSTEM

(IF IT HOLDS DEEP VACUUM)
CHARGE SYSTEM
A95425
Fig. 31 – Triple Evacuation Method
33
TROUBLESHOOTING WITH SUPERHEAT
This troubleshooting routine was developed to diagnose cooling Low Superheat with Normal or Low Suction Pressure
problems using superheat in TXV systems. It is effective on heat NOTE: Normal or low suction pressure is considered for
pumps in cooling mode as well as air conditioners. The system R--22: < 80 psig, Puron: < 135 psig
must utilize a TXV as the expansion device in cooling mode.
1. Re--check airflow and then check sensing bulb tightness,
Basic Diagnostics orientation on vapor tube and is properly wrapped.
NOTE: When checking refrigerant charge and troubleshooting
S Low Superheat with Normal or Low Suction Pressure
operating systems, the indoor airflow has significant effect on the
If OK proceed to Step 2
determination. If you are at this stage, it is assumed you have
2. Check superheat at Vapor Service Valve and Pseudo
already checked the subcooling once and believe the charge is
Evaporator Superheat.
correct. From this point, the airflow must be verified prior to
proceeding, hence step 1 below. S If both are less than 2°F, TXV likely not controlling
1. Check or verify proper indoor airflow properly, i.e. stuck open --> REPLACE VALVE
S Indoor air filter S If superheat is higher than 15°F, proceed to Step 3

3. Perform TXV function check.
S Duct dampers and supply registers are open
S With system running, place sensing bulb in ice bath for
S Indoor coil for debris
∼1 minute --> superheat should increase.
2. Check subcooling at OD unit liquid service valve
⎯ If no response, Replace Valve
S Outdoor airflow (debris on coil, etc.)
⎯ If OK proceed to Step 4
S Set the subcooling at value listed on rating plate if
4. Check for even temperature distribution at outlet of each
standard lineset
circuit of evaporator
S Set the subcooling at the maximum of 10°F or value
S If greater than 15°F between circuits, distributor or coil
listed on rating plate if a long line application has a restriction.
3. Check superheat at OD unit vapor service valve.
S If OK proceed to Step 5
S If low (< 2°F), proceed to Low SuperHeat section.
Low Superheat with High Suction Pressure
S If between 2 and 20°F/11_C valve is probably operating NOTE: High suction pressure is considered for R--22: > ∼80 psig,
properly. Puron: > ∼135 psig. An application issue or other system
S If greater than 20°F/11_C, perform Pseudo Evaporator component failure typically causes this condition.
SuperHeat Instructions check as follows: 5. R--22 Systems: Check that proper valve used (not an
⎯ Check refrigerant pressure at vapor service valve and R--410A valve)
refrigerant temperature at outlet of evaporator. S If OK proceed to Step 6
⎯ Use suction line geometry (diameter and equivalent 6. Check airflow, sensing bulb tightness, orientation on vapor
length), unit capacity and Tables 7 and 8 to determine tube and ensure bulb is properly wrapped.
suction pressure drop. S If OK proceed to Step 7
S For standard lineset diameters (vapor service 7. Check that compressor is pumping properly
valve diameters and larger) and lengths (less than
NOTE: Loose Rules of Thumb: Is discharge saturated ∼20°F
80 ft), generally no pressure adjustment (per
higher than ambient temperature? Is discharge superheat between
Table 6 or 7) is required.
15 and 50?
S For longer (greater than 80 ft) and small diameter .
linesets (less than service valve size), correct
pressure (add to gauge pressure reading) per 8. Recheck Airflow and Subcooling.
Tables 6 and 7. S If OK proceed to Replace Valve
S If Pseudo Superheat is greater than 15, proceed to High High Superheat with Normal or Low Pressure
SuperHeat section. NOTE: Normal or low suction pressure is considered:
S If Pseudo Evaporator Superheat is between 2 and 15, R--22 < 80 psig, Puron < 135 psig.
TXV appears to be functioning properly. 9. Check for restriction in liquid line (kinked line, filter drier
S If operation erratic (hunting), proceed to Hunting restricted, etc.)
Superheat °F Superheat in repetition section. S If OK proceed to Step 10
NOTE: Hunting is when the valve superheat swings more than 10. Check for restriction in suction line (kink, restricted suction
filter drier etc.))
10_.
11. Check power element cap tube is not broken
12. Check that equalizer tube is not kinked or plugged
13. Check that inlet screen (R--22 systems) is not restricted
14. Replace Valve
34
High Superheat with Normal or High Suction Pressure Pseudo Evaporator Superheat Instructions
NOTE: Normal to High suction pressure is considered The Pseudo Evaporator Superheat calculates the superheat at the
for R--22: > ∼65 psig, Puron: > ∼110 psig. An application issue or outlet of the evaporator with known and available information.
other system component failure typically causes this condition. Because there generally is not a pressure port on the vapor line at
15. Check airflow, sensing bulb tightness, orientation on vapor the indoor coil, this procedure allows the service personnel to
tube and ensure bulb is properly wrapped. evaluate the evaporator superheat with the vapor pressure port at
the outdoor unit.
S If OK proceed to Step 16 The method requires the following information:
16. R--410A Systems: Make sure proper valve is used (Not
S Suction line temperature at the outlet of the evaporator
R--22)
(°F).
S Suction line pressure at the outdoor unit (psig).
17. Check for even temperature distribution at outlet of each
circuit of evaporator S Outdoor nominal unit size (btuh).
S If OK proceed to Step 18 S Suction line equivalent line length (ft).
18. Check for high evaporator load: Return Air Leaks, high S Suction line pressure drop from tables (Table 6 and Table
indoor wet bulb and/or dry bulb temp, undersized system, 7).
etc. S Pressure--Temperature relationship for refrigerant used
S If OK proceed to Step 19 (P--T Chart).
19. Check that compressor is pumping properly If system uses a vapor line the same size as vapor service valve
S Loose Rule of Thumb: Is discharge saturated ∼20°F fitting or larger AND the line set equivalent length is 80 feet or
higher than ambient temperature? Is discharge superheat less, the pressure drop in vapor line of line set can be ignored.
between 15_F and 50_F? 1. Take suction line temperature at outlet of evaporator at
Hunting Superheat indoor unit.
2. Take suction service valve pressure at OD unit.
NOTE: Hunting is when the valve superheat swings more than
10°F Superheat in repetition. This is typically an application issue. 3. Determine lineset vapor line equivalent length and tube
diameter.
20. Check for obvious kinked or pinched distributor (capillary)
tubes causing imbalance to the circuiting. 4. Determine suction line pressure drop from Table 6 (Puron)
or Table 7 (R--22).
5. Calculate Pseudo Evaporator Superheat.
21. Check that proper size valve is used per Product Literature.
S Add the suction line pressure drop to the pressure
S If OK proceed to Step 22 reading obtained at suction service valve.
22. Check airflow, sensing bulb tightness, orientation on vapor NOTE: For nominal and larger diameter vapor lines with standard
tube and ensure bulb is properly wrapped. length linesets (vapor line same size as service valve fitting size and
S If OK proceed to Step 23 larger with equivalent length less than 80 ft) the pressure drop can
23. Check for even temperature distribution (±5° difference) at be ignored – use vapor service valve pressure and evaporator outlet
outlet of each circuit of evaporator and for even air temperature to calculate superheat
distribution over all evaporator slabs S Determine saturated evaporator temperature from a
S If OK proceed to Step 24. refrigerant pressure temperature relationship chart (PT
24. Move sensing bulb further down suction line. chart).
S If problem not corrected, replace valve S Subtract saturated evaporator from evaporator suction
line temperature to obtain evaporator superheat.
90° STD
90° LONG RAD 45° STD
A01058
Fig. 32 – Tube Fitting Geometry
Table 5—Fitting Losses in Equivalent Feet
TUBE SIZE OD
90° STD (A) 90° LONG RAD (B) 45° STD (C)
(IN.)
1/2 1.2 0.8 0.6
5/8 1.6 1.0 0.8
3/4 1.8 1.2 0.9
7/8 2.0 1.4 1.0
1---1/8 2.6 1.7 1.3
35
Table 6—Puron System Suction Pressure Drop
Nominal Suction Line Pressure Suction Puron Suction Line Pressure Drop (psig)
Size OD Drop Velocity Total Equivalent Line Length (ft)
(Btuh) (in.) (psi/100 ft) fpm 20 50 80 100 125 150 175 200 225 250
18000 1/2 9.9 1649 2 5 8 10 12 15 17 20 22 25
18000 5/8 3.1 1018 1 2 2 3 4 5 5 6 7 8
18000 3/4 1.2 678 0 1 1 1 1 2 2 2 3 3
1/2 16.7 2199 3 8 13 17 21 25 29 33 38 42
24000 5/8 5.2 1357 1 3 4 5 7 8 9 10 12 13
24000 3/4 2.0 904 0 1 2 2 2 3 3 4 4 5
24000 7/8 1.0 678 0 0 1 1 1 1 2 2 2 2
30000 5/8 7.8 1696 2 4 6 8 10 12 14 16 18 20
30000 3/4 2.9 1130 1 1 2 3 4 4 5 6 7 7
30000 7/8 1.5 848 0 1 1 1 2 2 3 3 3 4
36000 5/8 10.9 2036 2 5 9 11 14 16 19 22 24 27
36000 3/4 4.1 1356 1 2 3 4 5 6 7 8 9 10
36000 7/8 2.0 1017 0 1 2 2 3 3 4 4 5 5
42000 5/8 14.1 2375 3 7 11 14 18 21 25 28 32 35
42000 3/4 5.4 1582 1 3 4 5 7 8 9 11 12 14
42000 7/8 2.7 1187 1 1 2 3 3 4 5 5 6 7
42000 1 1/8 0.8 696 0 0 1 1 1 1 1 2 2 2
48000 3/4 6.9 1808 1 3 6 7 9 10 12 14 16 17
48000 7/8 3.5 1357 1 2 3 3 4 5 6 7 8 9
48000 1 1/8 1.0 796 0 0 1 1 1 1 2 2 2 2
60000 3/4 10.4 2260 2 5 8 10 13 16 18 21 23 26
60000 7/8 5.2 1696 1 3 4 5 6 8 9 10 12 13
60000 1 1/8 1.4 995 0 1 1 1 2 2 3 3 3 4
Line set application not recommended
Example 1 NOTE: The additional superheat at the compressor is due

While on a service call, after checking for proper indoor and principally to heat gain in the 75 feet of suction line with a minor
outdoor airflow, Tom finds the following pressures and contribution by the pressure drop. Because the suction line of the
temperatures at the service valves of a Puron air conditioner: lineset was the same size as the vapor service valve fitting and less
S Liquid line pressure = 340 psig than 80 feet, Tom could have ignored the pressure drop in the
suction line and obtained the evaporator superheat by using the
S Liquid line temperature = 97°F vapor service valve pressure of 125 psig (saturated temperature =
S Suction line pressure = 125 psig 43°F) and the evaporator outlet temperature of 53°F. The
S Suction line temperature = 70°F evaporator superheat is calculated to be (53°F – 43°F =) 10 °F.
Using a Puron PT chart, the subcooling is determined to be 8°F,
which is within ±3 of the 10°F listed on the rating plate. Tom
believes the charge is correct. He calculates the superheat to be
approximately 27°F superheat. The apparently high superheat has
Tom concerned.
Tom uses the Pseudo Evaporator Superheat method to check the
TXV performance. The system is a 3--ton Puron air conditioner
with 75 feet equivalent length of 3/4” suction line. Based on Table
6, the system has approximately 3--psig pressure drop in the vapor
line. Per the instructions, he takes the suction line temperature at
the outlet of the evaporator and finds it to be 53°F. Tom adds 3
psig to the 125--psig suction pressure at the outdoor unit to get 128
psig evaporator pressure. The saturated pressure of 128 equates to
44°F. Tom calculates the evaporator superheat to be (53°F -- 44°F
=) 9°F. The TXV appears to be operating properly.
36
Table 7—R--22 System Suction Pressure Drop
Nominal Line Pressure Suction R ---22 Suction Line Pressure Drop (psig)
Size OD Drop Velocity Total Equivalent Line Length (ft)
(Btuh) (in.) (psi/100 ft) Fpm 20 50 80 100 125 150 175 200 225 250
18000 5/8 13.6 2563 3 7 11 14 17 20 24 27 31 34
18000 5/8 4.0 1539 1 2 3 4 5 6 7 8 9 10
18000 3/4 1.5 1025 0 1 1 1 2 2 3 3 3 4
18000 7/8 0.8 769 0 0 1 1 1 1 1 2 2 2
24000 5/8 6.7 2052 1 3 5 7 8 10 12 13 15 17
24000 3/4 2.5 1367 1 1 2 3 3 4 4 5 6 6
24000 7/8 1.3 1026 0 1 1 1 2 2 2 3 3 3
30000 5/8 10.1 2565 2 5 8 10 13 15 18 20 23 25
30000 3/4 3.8 1708 1 2 3 4 5 6 7 8 9 9
30000 7/8 1.9 1282 0 1 2 2 2 3 3 4 4 5
36000 3/4 5.3 2050 1 3 4 5 7 8 9 11 12 13
36000 7/8 2.6 1538 1 1 2 3 3 4 5 5 6 7
36000 1 1/8 0.7 902 0 0 1 1 1 1 1 1 2 2
42000 3/4 7.0 2392 1 3 6 7 9 10 12 14 16 17
42000 7/8 3.5 1795 1 2 3 3 4 5 6 7 8 9
42000 1 1/8 1.0 1053 0 0 1 1 1 1 2 2 2 2
48000 3/4 8.9 2733 2 4 7 9 11 13 16 18 20 22
48000 7/8 4.4 2051 1 2 4 4 6 7 8 9 10 11
48000 1 1/8 1.2 1203 0 1 1 1 2 2 2 2 3 3
60000 7/8 6.7 2564 1 3 5 7 8 10 12 13 15 17
60000 1 1/8 1.8 1504 0 1 1 2 2 3 3 4 4 5
60000 1 3/8 0.7 987 0 0 1 1 1 1 1 1 2 2
Line set application not recommended
Example 2 Examining the lineset, Jason finds approximately 145 ft of suction

Jason is servicing a 5--ton R--22 air conditioner with 7/8” suction line with 4 long radius elbows. Per Fig. 33 and Table 7, each
line. As part of his basic inspection he believes he has normal fitting has an equivalent length of 1.4 ft. The total equivalent
airflow because the air filters are clean, ductwork appears to be length of the suction line is (145’ + (4 * 1.4’) ≈) 150 ft. Based on
properly sized and in good shape and the evaporator coil is clean. Table 9, Jason determines there should be 10--psig pressure--drop
He then checks the superheat and subcooling at the outdoor unit in the suction line.
service valves. Taking pressures and temperatures he finds the Jason now takes the suction line temperature at the outlet of the
following: evaporator and obtains 51°F. Per the instructions, Jason adds the
S Liquid line pressure = 260 psig 10--psig pressure--drop to the 60--psig pressure at the outdoor unit
to get 70--psig at the evaporator. Saturated pressure of 70--psig
S Liquid line temperature = 110°F equates to approximately 41°F. Jason determines the Evaporator
S Suction line pressure = 60 psig superheat to be (51°F -- 41°F =) 10°F. Jason concludes the TXV is
functioning properly.
S Suction line temperature = 65°F
NOTE: In this situation, both the pressure drop and the heat gain
Using an R--22 PT relationship, Jason calculates the subcooling to in the suction line are significant contributions to the superheat at
be approximately 10°F with 30°F superheat. Because the
the service valve. The pressure drop contributes approximately
subcooling is correct but the superheat appears to be high, he is
7°F superheat and the heat gain in the suction line contributes
concerned and decides to perform the Pseudo Evaporator
13°F.
Superheat check.
Fig. 33 – Pseudo Evaporator Superheat Pressure and Temperature Measurement Locations
37
Table 8—Puronr Refrigerant Pressure Temperature Chart
PSIG
PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F
12 --38.2 118 39.9 224 76.9 330 102.9 436 123.3 542 140.2
14 --35.3 120 40.8 226 77.4 332 103.3 438 123.6 544 140.5
16 --32.5 122 41.6 228 78.0 334 103.7 440 124.0 546 140.8
18 --29.9 124 42.5 230 78.5 336 104.1 442 124.3 548 141.1
20 --27.3 126 43.3 232 79.1 338 104.6 444 124.7 550 141.4
22 --24.9 128 44.2 234 79.7 340 105.0 446 125.0 554 141.9
24 --22.6 130 45.0 236 80.2 342 105.4 448 125.3 558 142.5
26 --20.4 132 45.8 238 80.7 344 105.8 450 125.7 560 142.8
28 --18.3 134 46.6 240 81.3 346 106.2 452 126.0 564 143.4
30 --16.2 136 47.5 242 81.8 348 106.6 454 126.4 568 143.9
32 --14.2 138 48.2 244 82.4 350 107.0 456 126.7 570 144.2
34 --12.3 140 49.0 246 82.9 352 107.5 458 127.0 574 144.8
36 --10.4 142 49.8 248 83.4 354 107.9 460 127.4 578 145.3
38 --8.6 144 50.6 250 83.9 356 108.3 462 127.7 580 145.6
40 --6.9 146 51.4 252 84.5 358 108.7 464 128.0 584 146.2
42 --5.1 148 52.1 254 85.0 360 109.1 466 128.4 588 146.7
44 --3.5 150 52.9 256 85.5 362 109.5 468 128.7 590 147.0
46 --1.9 152 53.6 258 86.0 364 109.9 470 129.0 594 147.5
48 --0.3 154 54.4 260 86.5 366 110.3 472 129.4 598 148.1
50 1.3 156 55.1 262 87.0 368 110.7 474 129.7 600 148.4
52 2.8 158 55.8 264 87.5 370 111.1 476 130.0 604 148.9
54 4.2 160 56.5 266 88.0 372 111.5 478 130.3 606 149.2
56 5.7 162 57.3 268 88.5 374 111.9 480 130.7 608 149.4
58 7.1 164 58.0 270 89.0 376 112.2 482 131.0 610 151.3
60 8.5 166 58.7 272 89.5 378 112.6 484 131.3 612 150.0
62 9.8 168 59.4 274 90.0 380 113.0 486 131.6 614 150.2
64 11.1 170 60.1 276 90.5 382 113.4 488 131.9 616 150.5
66 12.4 172 60.7 278 91.0 384 113.8 490 132.3 618 150.7
68 13.7 174 61.4 280 91.5 386 114.2 492 132.6 620 151.0
70 15.0 176 62.1 282 92.0 388 114.6 494 132.9 624 151.5
72 16.2 178 62.8 284 92.4 390 114.9 496 133.2 626 151.8
74 17.4 180 63.4 286 92.9 392 115.3 498 133.5 628 152.1
76 18.6 182 64.1 288 93.4 394 115.7 500 133.8 630 152.3
78 19.8 184 64.7 290 93.9 396 116.1 502 134.1 634 152.8
80 20.9 186 65.4 292 94.3 398 116.4 504 134.5 636 153.1
82 22.0 188 66.0 294 94.8 400 116.8 506 134.8 638 153.3
84 23.2 190 66.7 296 95.3 402 117.2 508 135.1 640 153.6
86 24.3 192 67.3 298 95.7 404 117.5 510 135.4 644 154.1
88 25.3 194 67.9 300 96.2 406 117.9 512 135.7 646 154.3
90 26.4 196 68.6 302 96.7 408 118.3 514 136.0 648 154.6
92 27.4 198 69.2 304 97.1 410 118.6 516 136.3 650 154.8
94 28.5 200 69.8 306 97.6 412 119.0 518 136.6 654 161.8
96 29.5 202 70.4 308 98.0 414 119.4 520 136.9 656 155.6
98 30.5 204 71.0 310 98.5 416 119.7 522 137.2 658 155.8
100 31.5 206 71.6 312 98.9 418 120.1 524 137.5 660 158.3
102 32.5 208 72.2 314 99.4 420 120.5 526 137.8 664 156.6
104 33.4 210 72.8 316 99.8 422 120.8 528 138.1 666 156.8
106 34.4 212 73.4 318 100.2 424 121.2 530 138.4 668 157.1
108 35.3 214 74.0 320 100.7 426 121.5 532 138.7 670 157.3
110 36.3 216 74.6 322 101.1 428 121.9 534 139.0 674 157.7
112 37.2 218 75.1 324 101.6 430 122.2 536 139.3 676 158.0
114 38.1 220 75.7 326 102.0 432 122.6 538 139.6 Critical Point
116 39.0 222 76.3 328 102.4 434 122.9 540 139.9 705 163.0
Source: Allied Signal -- Genetron for Windows version R1.0 © 1999
38
Table 9—R--22 Refrigerant Pressure Temperature Relationship
psig °F psig °F psig °F psig °F psig °F psig °F psig °F
7 --25.9 71 41.7 135 76.2 199 101.1 263 120.9 327 137.5 391 152.0
8 --24.0 72 42.3 136 76.7 200 101.4 264 121.1 328 137.8 392 152.2
9 --22.1 73 43.0 137 77.1 201 101.7 265 121.4 329 138.0 393 152.4
10 --20.4 74 43.7 138 77.6 202 102.1 266 121.7 330 138.2 394 152.6
11 --18.7 75 44.3 139 78.0 203 102.4 267 122.0 331 138.5 395 152.8
12 --17.0 76 45.0 140 78.4 204 102.8 268 122.3 332 138.7 396 153.1
13 --15.4 77 45.6 141 78.9 205 103.1 269 122.5 333 139.0 397 153.3
14 --13.8 78 46.2 142 79.3 206 103.4 270 122.8 334 139.2 398 153.5
15 --12.3 79 46.9 143 79.7 207 103.8 271 123.1 335 139.4 399 153.7
16 --10.8 80 47.5 144 80.2 208 104.1 272 123.4 336 139.7 400 153.9
17 --9.3 81 48.1 145 80.6 209 104.4 273 123.6 337 139.9 401 154.1
18 --7.9 82 48.7 146 81.0 210 104.8 274 123.9 338 140.2 402 154.3
19 --6.5 83 49.4 147 81.4 211 105.1 275 124.2 339 140.4 403 154.5
20 --5.2 84 50.0 148 81.8 212 105.4 276 124.5 340 140.6 404 154.7
21 --3.9 85 50.6 149 82.3 213 105.7 277 124.7 341 140.9 405 154.9
22 --2.6 86 51.2 150 82.7 214 106.1 278 125.0 342 141.1 406 155.1
23 --1.3 87 51.8 151 83.1 215 106.4 279 125.3 343 141.3 407 155.3
24 0.0 88 52.4 152 83.5 216 106.7 280 125.5 344 141.6 408 155.6
25 1.2 89 52.9 153 83.9 217 107.0 281 125.8 345 141.8 409 155.8
26 2.4 90 53.5 154 84.3 218 107.4 282 126.1 346 142.0 410 156.0
27 3.6 91 54.1 155 84.7 219 107.7 283 126.4 347 142.3 411 156.2
28 4.7 92 54.7 156 85.1 220 108.0 284 126.6 348 142.5 412 156.4
29 5.8 93 55.2 157 85.5 221 108.3 285 126.9 349 142.7 413 156.6
30 6.9 94 55.8 158 85.9 222 108.6 286 127.2 350 142.9 414 156.8
31 8.0 95 56.4 159 86.3 223 108.9 287 127.4 351 143.2 415 157.0
32 9.1 96 56.9 160 86.7 224 109.3 288 127.7 352 143.4 416 157.2
33 10.2 97 57.5 161 87.1 225 109.6 289 127.9 353 143.6 417 157.4
34 11.2 98 58.0 162 87.5 226 109.9 290 128.2 354 143.9 418 157.6
35 12.2 99 58.6 163 87.9 227 110.2 291 128.5 355 144.1 419 157.8
36 13.2 100 59.1 164 88.3 228 110.5 292 128.7 356 144.3 420 158.0
37 14.2 101 59.7 165 88.7 229 110.8 293 129.0 357 144.5 421 158.2
38 15.2 102 60.2 166 89.1 230 111.1 294 129.3 358 144.8 422 158.4
39 16.2 103 60.7 167 89.5 231 111.4 295 129.5 359 145.0 423 158.6
40 17.1 104 61.3 168 89.9 232 111.8 296 129.8 360 145.2 424 158.8
41 18.1 105 61.8 169 90.2 233 112.1 297 130.0 361 145.4 425 159.0
42 19.0 106 62.3 170 90.6 234 112.4 298 130.3 362 145.7 426 159.2
43 19.9 107 62.8 171 91.0 235 112.7 299 130.6 363 145.9 427 159.4
44 20.8 108 63.3 172 91.4 236 113.0 300 130.8 364 146.1 428 159.6
45 21.7 109 63.9 173 91.8 237 113.3 301 131.1 365 146.3 429 159.8
46 22.6 110 64.4 174 92.1 238 113.6 302 131.3 366 146.6 430 160.0
47 23.5 111 64.9 175 92.5 239 113.9 303 131.6 367 146.8 431 160.2
48 24.3 112 65.4 176 92.9 240 114.2 304 131.8 368 147.0 432 160.4
49 25.2 113 65.9 177 93.2 241 114.5 305 132.1 369 147.2 433 160.6
50 26.0 114 66.4 178 93.6 242 114.8 306 132.3 370 147.5 434 160.8
51 26.8 115 66.9 179 94.0 243 115.1 307 132.6 371 147.7 435 161.0
52 27.6 116 67.4 180 94.3 244 115.4 308 132.8 372 147.9 436 161.2
53 28.4 117 67.9 181 94.7 245 115.7 309 133.1 373 148.1 437 161.4
54 29.2 118 68.4 182 95.1 246 116.0 310 133.3 374 148.3 438 161.6
55 30.0 119 68.8 183 95.4 247 116.3 311 133.6 375 148.6 439 161.8
56 30.8 120 69.3 184 95.8 248 116.6 312 133.8 376 148.8 440 162.0
57 31.6 121 69.8 185 96.2 249 116.8 313 134.1 377 149.0 441 162.2
58 32.4 122 70.3 186 96.5 250 117.1 314 134.3 378 149.2 442 162.3
59 33.1 123 70.7 187 96.9 251 117.4 315 134.6 379 149.4 443 162.5
60 33.9 124 71.2 188 97.2 252 117.7 316 134.8 380 149.6 444 162.7
61 34.6 125 71.7 189 97.6 253 118.0 317 135.1 381 149.9 445 162.9
62 35.4 126 72.2 190 97.9 254 118.3 318 135.3 382 150.1 446 163.1
63 36.1 127 72.6 191 98.3 255 118.6 319 135.6 383 150.3 447 163.3
64 36.8 128 73.1 192 98.6 256 118.9 320 135.8 384 150.5 448 163.5
65 37.5 129 73.5 193 99.0 257 119.2 321 136.1 385 150.7 449 163.7
66 38.2 130 74.0 194 99.3 258 119.4 322 136.3 386 150.9 450 163.9
67 38.9 131 74.5 195 99.7 259 119.7 323 136.6 387 151.1
68 39.6 132 74.9 196 100.0 260 120.0 324 136.8 388 151.4 Critical
69 40.3 133 75.4 197 100.4 261 120.3 325 137.0 389 151.6 709 205.1
70 41.0 134 75.8 198 100.7 262 120.6 326 137.3 390 151.8
39
Table 10—Puron Subcooling Chart
Liquid Line Temperature (_F)
Liq Press P---T Subcooling (_F)
(psig) (_F)
2 4 6 8 10 12 14 16 18 20
200 70 68 66 64 62 60 58 56 54 52 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 92 90 88 86 84 82 80 78 76 74 72
290 94 92 90 88 86 84 82 80 78 76 74
300 96 94 92 90 88 86 84 82 80 78 76
310 99 97 95 93 91 89 87 85 83 81 79
320 101 99 97 95 93 91 89 87 85 83 81
330 103 101 99 97 95 93 91 89 87 85 83
340 105 103 101 99 97 95 93 91 89 87 85
350 107 105 103 101 99 97 95 93 91 89 87
360 109 107 105 103 101 99 97 95 93 91 89
370 111 109 107 105 103 101 99 97 95 93 91
380 113 111 109 107 105 103 101 99 97 95 93
390 115 113 111 109 107 105 103 101 99 97 95
400 117 115 113 111 109 107 105 103 101 99 97
410 119 117 115 113 111 109 107 105 103 101 99
420 121 119 117 115 113 111 109 107 105 103 101
430 122 120 118 116 114 112 110 108 106 104 102
440 124 122 120 118 116 114 112 110 108 106 104
450 126 124 122 120 118 116 114 112 110 108 106
460 127 125 123 121 119 117 115 113 111 109 107
470 129 127 125 123 121 119 117 115 113 111 109
480 131 129 127 125 123 121 119 117 115 113 111
490 132 130 128 126 124 122 120 118 116 114 112
500 134 132 130 128 126 124 122 120 118 116 114
510 135 133 131 129 127 125 123 121 119 117 115
520 137 135 133 131 129 127 125 123 121 119 117
530 139 137 135 133 131 129 127 125 123 121 119
540 140 138 136 134 132 130 128 126 124 122 120
550 141 139 137 135 133 131 129 127 125 123 121
560 143 141 139 137 135 133 131 129 127 125 123
570 144 142 140 138 136 134 132 130 128 126 124
580 146 144 142 140 138 136 134 132 130 128 126
590 147 145 143 141 139 137 135 133 131 129 127
600 149 147 145 143 141 139 137 135 133 131 129
610 150 148 146 144 142 140 138 136 134 132 130
40
Table 11—Puron Superheat Chart
Vapor Line Temperature (°F)
Vap Press P--T Superheat (°F)
(psig) (°F) 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
80 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51
82 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52
84 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53
86 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54
88 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55
90 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
92 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57
94 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59
96 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
98 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61
100 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62
102 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63
104 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64
106 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65
108 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65
110 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66
112 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67
114 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68
116 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69
118 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70
120 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71
122 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72
124 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73
126 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
128 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
130 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75
132 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76
134 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77
136 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78
138 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78
140 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79
142 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80
144 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81
146 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82
148 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82
150 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83
152 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84
154 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85
156 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85
158 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86
160 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87
162 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88
41
Table 12—R--22 Subcooling Chart
R---22 Liquid Line Temperature (_F)

Liquid
Subcooling (_F)
Pres PT (°F)
(psig) 2 4 6 8 10 12 14 16 18 20 22 24 26
120 70 68 66 64 62 60 58 56 54 52 50 48 46 44
125 72 70 68 66 64 62 60 58 56 54 52 50 48 46
130 74 72 70 68 66 64 62 60 58 56 54 52 50 48
135 76 74 72 70 68 66 64 62 60 58 56 54 52 50
140 79 77 75 73 71 69 67 65 63 61 59 57 55 53
145 81 79 77 75 73 71 69 67 65 63 61 59 57 55
150 83 81 79 77 75 73 71 69 67 65 63 61 59 57
155 85 83 81 79 77 75 73 71 69 67 65 63 61 59
160 87 85 83 81 79 77 75 73 71 69 67 65 63 61
165 89 87 85 83 81 79 77 75 73 71 69 67 65 63
170 91 89 87 85 83 81 79 77 75 73 71 69 67 65
175 93 91 89 87 85 83 81 79 77 75 73 71 69 67
180 95 93 91 89 87 85 83 81 79 77 75 73 71 69
185 96 94 92 90 88 86 84 82 80 78 76 74 72 70
190 98 96 94 92 90 88 86 84 82 80 78 76 74 72
195 100 98 96 94 92 90 88 86 84 82 80 78 76 74
200 102 100 98 96 94 92 90 88 86 84 82 80 78 76
205 103 101 99 97 95 93 91 89 87 85 83 81 79 77
210 105 103 101 99 97 95 93 91 89 87 85 83 81 79
215 107 105 103 101 99 97 95 93 91 89 87 85 83 81
220 108 106 104 102 100 98 96 94 92 90 88 86 84 82
225 110 108 106 104 102 100 98 96 94 92 90 88 86 84
230 111 109 107 105 103 101 99 97 95 93 91 89 87 85
235 113 111 109 107 105 103 101 99 97 95 93 91 89 87
240 114 112 110 108 106 104 102 100 98 96 94 92 90 88
245 116 114 112 110 108 106 104 102 100 98 96 94 92 90
250 117 115 113 111 109 107 105 103 101 99 97 95 93 91
255 119 117 115 113 111 109 107 105 103 101 99 97 95 93
260 120 118 116 114 112 110 108 106 104 102 100 98 96 94
265 121 119 117 115 113 111 109 107 105 103 101 99 97 95
270 123 121 119 117 115 113 111 109 107 105 103 101 99 97
275 124 122 120 118 116 114 112 110 108 106 104 102 100 98
280 126 124 122 120 118 116 114 112 110 108 106 104 102 100
285 127 125 123 121 119 117 115 113 111 109 107 105 103 101
290 128 126 124 122 120 118 116 114 112 110 108 106 104 102
295 129 127 125 123 121 119 117 115 113 111 109 107 105 103
300 131 129 127 125 123 121 119 117 115 113 111 109 107 105
305 132 130 128 126 124 122 120 118 116 114 112 110 108 106
310 133 131 129 127 125 123 121 119 117 115 113 111 109 107
315 135 133 131 129 127 125 123 121 119 117 115 113 111 109
320 136 134 132 130 128 126 124 122 120 118 116 114 112 110
325 137 135 133 131 129 127 125 123 121 119 117 115 113 111
330 138 136 134 132 130 128 126 124 122 120 118 116 114 112
42
Table 13—R--22 Superheat Chart
R---22 Vapor Line Temperature (_F)

Vapor Superheat (_F)
Press PT (°F)
(psig) 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
50 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
51 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57
52 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
53 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
54 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59
55 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
56 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61
57 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62
58 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62
59 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63
60 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64
61 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65
62 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65
63 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66
64 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67
65 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68
66 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68
67 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69
68 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70
69 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70
70 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71
71 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72
72 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72
73 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73
74 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
75 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
76 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75
77 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76
78 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76
79 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77
80 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78
81 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78
82 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79
83 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80
84 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80
85 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81
86 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81
87 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82
88 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83
89 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83
90 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84
91 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84
92 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85
43
TWO--STAGE 25HNA/24ANA
Application Guidelines Model Plug
Carrier designed and tested the two--stage air conditioner and heat Each control board contains a model plug. The correct model plug
pump products with Puron refrigerant to operate at a minimum must be installed in order for the system to operate properly. (See
outdoor operating ambient in cooling mode at 55_F without low Table 14.)
ambient cooling enabled and the maximum outdoor operating The model plug is used to identify the type and size of unit to the
ambient in cooling is 125_F/51.6_C. On Infinity communicating control. On 25HNA6 models, the model plug is also used to
systems, only low ambient cooling is available to 0_F/--17.8_C. determine the start sequence timing for each individual model.
The maximum outdoor operating ambient in heating mode is On new units, the model and serial numbers are inputted into the
66_F/18.8_C on all heat pumps. Continuous operation in heating board’s memory at the factory. If a model plug is lost or missing at
mode is approved to --30_F/--34.4_C. Thermostat options for the initial installation, the unit will operate according to the
two stage units are as follows: information input at the factory and the appropriate error code will
S Bristol reciprocating two stage units can utilize either a flash temporarily. An RCD replacement board contains no model
two stage thermostat or an Infinity communicating User and serial information. If the factory control board fails, the model
Interface. plug must be transferred from the original board to the replacement
board for the unit to operate.
S Copeland scroll two stage units must use the Infinity
communicating User Interface. NOTE: The model plug takes priority over factory model
information input at the factory. If the model plug is removed after
25HNA9 Copeland scroll units require Infinity communicating
initial power up, the unit will operate according to the last valid
User Interface (UI) to achieve the needed airflow for comfort and
model plug installed, and flash the appropriate fault code
efficiency in both low and high stage. The Copeland scroll two
stage compressor unloads to 67% of full compressor capacity temporarily.
verses the Bristol reciprocating two stage compressor that decreases Table 14—Model Plug Information
to about 50% of full capacity. PIN RESISTANCE
Indoor units for the two stage require variable speed indoor blower MODEL
MODEL (K---ohms)
PLUG
capabilities. Only unit combinations listed in the two stage NUMBER
NUMBER
Product Data are recommended. Product Data may also include Pins 1---4 Pins 2---3
coil only ratings but a variable speed blower is required to achieve
25HNA624 HK70EZ002 5.1 18
comfort and efficiency.
25HNA636 HK70EZ004 5.1 33
Non--communicating indoor units with properly matched airflow
25HNA648 HK70EZ006 5.1 51
are available for the 25HNA6/24ANA7 models and are listed in
the Product Data. There are no non--communicating indoor units 25HNA660 HK70EZ008 5.1 75
available with the proper airflow for the 25HNA9/24ANA1 units.
For this reason, a User Interface (Infinity Control) and Infinity 25HNA924 HK70EZ010 5.1 120
indoor unit is required with the Copeland UltraTech unit 25HNA936 HK70EZ012 5.1 180
(25HNA9/24ANA1). 25HNA948 HK70EZ014 5.1 270
25HNA6/24ANA7 Bristol Compressor units may use a standard 25HNA960 HK70EZ016 11 5.1
2--stage thermostat, or for full utilization of features, the Infinity
zoned or non--zoned control. 24ANA124 HK70EZ009 5.1 91
Line sets for two stage units are similar to the single stage units. 24ANA136 HK70EZ011 5.1 150
However, some restrictions may apply to specific combinations in 24ANA148 HK70EZ013 5.1 220
long line applications. Refer to the Long Line Guideline for further 24ANA160 HK70EZ015 5.1 360
information.
The Tennessee Valley Authority (TVA) requires that electric strip 24ANA724 HK70EZ001 5.1 11
heat have a lockout feature. This is achieved through Carrier
24ANA736 HK70EZ003 5.1 24
thermostats required per above and must be used on all TVA
24ANA748 HK70EZ006 5.1 39
approved units.
24ANA760 HK70EZ007 5.1 62
The new control board in the two stage units with Puron refrigerant
has dip switches for defrost timing. The Infinity controls provide
these two stage units with high stage latching and Hybrid Heatt
(dual fuel) capabilities. The standard Hybrid Heatt (duel fuel)
thermostat can be used on two stage units with Bristol
reciprocating compressors only.
NOTE: Refer to Application Guideline 38--11SM for
38TDB/38YDB information.
44
Airflow Selections for 24ANA7 / 25HNA6 / S Low pressure switch is ignored for first 3 minutes during
24ANA124,36,48A0032 / 24ANA160A0033 / low ambient start up. After 3 minutes, if LPS trips, then
outdoor fan motor is turned off for 10 minutes, with the
25HNA924,36,48A0032,25HNA960A0033 with
compressor running. If LPS closes within 10 minutes
serial number 3809 and later Using then cooling continues with the outdoor fan cycling per
Non--Communicating (Non--Infinity) Thermostats the coil temperature routine listed above for the
Airflow Selection for 58CVA/58MVB Furnaces remainder of the cooling cycle. If the LPS does not close
within 10 minutes, then the normal LPS trip response
The 58CVA/58MVB variable--speed furnaces provide high--and
(shut down cooling operation and generate LPS trip
low--stage blower operation to match the capacities of the
error) will occur.
compressor at high and low stages. To select the recommended
airflow and for adjustments to the manual switches labeled SW1--5, For 24ANA1/25HNA9 models, the PWM output for both high and
AC, and CF on the control board, refer to the furnace Installation low stage equals the value for low stage operation below 104_F.
Instructions. The 58CVA/58MVB utilizes a control center that Defrost
allows the installing technician to select the proper airflows. The This control offers 5 possible defrost interval times: 30, 60, 90, 120
HP switch determines the airflow during high--stage compressor minutes, or AUTO.
operation. Airflow for high-- and low--stage can be calculated at
either 350 CFM per ton or 400 CFM per ton, based on the With non--communicating thermostats, these are selected by dip
positions of SW1--5. switches on the unit control board. With communicating
thermostats, the Infinity Control User Interface. The Infinity
When using communicating (Infinity) control, dipswitch Control selection overrides the control board dip switch settings.
adjustments are not necessary on furnaces. Airflows are
determined by Infinity Control setup. AUTO defrost adjusts the defrost interval time based on the last
defrost time as follows:
Airflow Selection for FV4 Fan Coils for 24ANA1,
S When defrost time <3 minutes, the next defrost
24ANA7, 25HNA6, 25HNA9 with serial number interval=120 minutes.
3809 and later Using Non--Communicating S When defrost time 3--5 minutes, the next defrost
(Non--Infinity) Thermostats interval=90 minutes.
The FV4 provides high-- and low--stage blower operation to match S When defrost time 5--7 minutes, the next defrost
the capacities of compressor at high-- and low--stage. To select interval=60 minutes.
recommended airflow, refer to FV4 Installation Instructions. The S When defrost time >7 minutes, the next defrost
FV4 utilizes an Easy Select control board that allows the installing
interval=30 minutes.
technician to select proper airflows. For adjustments to control
board, select appropriate HP SIZE and CFM ADJUST setting. This The control board accumulates compressor run time. As the
fan coil has an adjustable blower off delay factory set at 90 sec for accumulated run time approaches the selected defrost interval time,
high-- and low--stage blower operation. the control board monitors the coil temperature sensor for a defrost
demand. If a defrost demand exists, a defrost cycle will be initiated
For other combinations of equipment consult Product Data Digest.
at the end of the selected time interval. A defrost demand exists
GENERAL INFORMATION when the coil temperature is at or below 32_F for 4 minutes during
the interval.
Low Ambient Cooling
The defrost cycle is terminated when the coil temperature reaches
When this unit is operating below 55_F outdoor temperature, 65_F or 10 minutes has passed.
provisions must be made for low ambient operation.
On 25HNA6 models, defrost will occur in low-- or high--stage as
Infinity controlled low ambient cooling: demanded by the thermostat or User Interface regardless of OAT
This unit is capable of low ambient cooling without a kit ONLY On 25HNA9 models, when OAT is >25_F (--3.9_C), defrost will
when using Infinity control. A low ambient kit is not required, and occur in low-- or high--stage as demanded by the thermostat or
the outdoor fan motor does not need to be replaced for Infinity User Interface.
controlled low ambient operation. The Infinity Control provides an
automatic evaporator coil freeze protection algorithm that On 25HNA9 models, if OAT is ≤25_F (--3.9_C), defrost will
eliminates the need for an evaporator freeze thermostat. Low occur in high--stage only, regardless of thermostat or User Interface
ambient cooling must be enabled in the User Interface set up. Fan demand, and will terminate at 50_F (10_C) coil temperature with a
may not begin to cycle until about 40_F OAT. Fan will cycle minimum of 2.5 minutes in defrost.
based on coil and outdoor air temperature. If the coil temperature does not reach 32_F (0_C) within the
Infinity controlled low ambient mode operates as follows: interval, the interval timer will be reset and start over.
S Fan is OFF when outdoor coil temp is < (outdoor air S Upon initial power up the first defrost interval is
temperature + 3_F) or outdoor fan has been ON for 30 defaulted to 30 minutes. Remaining intervals are at
minutes. (Fan is turned off to allow refrigerant system to selected times.
stabilize.) S Defrost is only allowed to occur below 50_F (10_C)
S Fan is ON when outdoor coil temp > (outdoor air outdoor ambient temperature.
temperature + 25_F) or outdoor coil temp > 80_F or if The outdoor fan output (ODF) will remain off for 20 seconds after
outdoor fan has been OFF for 30 minutes. (Fan is turned termination. This delay will allow time for the system to capture
on to allow refrigerant system to stabilize.) the heat from the outdoor coil and reduce the “steam cloud” effect
that may occur on transition from defrost to the heating cycle. The
outdoor fan output OFF delay of 20 seconds may be defeated to
enable the fan to energize immediately at the time of termination
and 12 seconds prior to the reversing valve de--energizing, through
the User Interface setup screen available with SYSTXBBUID01--C
UI, or forced defrost pins as follows:
45
S The ODF fan delay defeat can be toggled by shorting the off mode, to prevent refrigerant migration into the unit through the
forced defrost pins for >15 seconds while in the standby liquid--line.
mode (status LED on solid). The LED will start to flash On Models with Accessory Liquid Solenoid Using a
when the toggle has taken place. Non--Communicating Thermostat:
S Status code 4 shows the fan delay defeat is active (no The liquid solenoid is connect to the Y1 and C terminal
delay) connections. The liquid solenoid closes, in the compressor off
mode, to prevent refrigerant migration into the unit through the
S Status code 3 shows that it is not active (20 second
liquid--line.
delay)
The code will continue to be displayed until after the short is CHECK CHARGE
removed. Once the short is removed, there is a 5 second wait All 25HNA6 units must be charged in high stage only.
before the code is cancelled. The code that is flashing will finish
before going back to sold LED. the control is shipped with the
ODF fan delay defeat NOT active. the change in status is
remembered until toggled to a new status. A power down / power
favorable for subcooling charging. Favorable conditions exist
up sequence will not reset the status. It may be necessary to do the
when the outdoor temperature is between 70_F and 100_F
toggle twice to cycle to the desired state of defeat.
(21.11_C and 37.78_C), and the indoor temperature is between
Defrost Hold 70_F and 80_F (21.11_C and 26.67_C). Follow the procedure
in a non--communicating system, if the thermostat becomes below:
satisfied (Y1 or Y1 and Y2) before the defrost cycle is terminated, Unit is factory charged for 15ft (4.57 m) of lineset. Adjust charge
the control will “hold” in defrost mode and finish the defrost cycle by adding or removing 0.6 oz/ft of 3/8 liquid line above or below
on the next call for heat. 15ft (4.57 m) respectively.
With communicating Infinity Control, defrost hold is not needed in For standard refrigerant line lengths (80 ft/24.38 m or less), allow
a communicating system because the User Interface will complete system to operate in cooling mode at least 15 minutes. If conditions
the defrost cycle before shutting down the system. are favorable, check system charge by subcooling method. If any
Forced Defrost adjustment is necessary, adjust charge slowly and allow system to
With non--communicating (non--Infinity) control, forced defrost operate for 15 minutes to stabilize before declaring a properly
can be initiated by manually shorting the 2--pin header labeled charged system.
FORCED DEFROST (see Fig 43) on the control board for 5 If the indoor temperature is above 80_F (26.67_C), and the
seconds then releasing. outdoor temperature is in the favorable range, adjust system charge
With communicating (Infinity) control, forced defrost is initiated by weight based on line length and allow the indoor temperature to
with the User Interface. drop to 80_F (26.67_C) before attempting to check system charge
On all models, during a Forced Defrost:
If the indoor temperature is below 70_F (21.11_C), or the outdoor
S If coil temperature is at defrost temperature of 32_F, and temperature is not in the favorable range, adjust charge for line set
outdoor air temperature is below 50_F, a full defrost length above or below 15ft (4.57 m) only. Charge level should then
sequence will occur. be appropriate for the system to achieve rated capacity. The charge
S If coil temperature or outdoor air temperature does not level could then be checked at another time when the both indoor
meet the above requirements, an abbreviated 30 second and outdoor temperatures are in a more favorable range.
defrost will occur. NOTE: If line length is beyond 80 ft (24.38 m) or greater than 20
Quiet Shift ft (6.10 m) vertical separation, See Long Line Guideline for
special charging requirements.
Quiet Shift is a field--selectable defrost mode which may eliminate
occasional noise that could be heard at the start of the defrost cycle Heating Check Chart Procedure
and restarting of the heating cycle. On models with a To check system operation during heating cycle, refer to the Heat
non--communicating system, this feature must be enabled by Pump Charging Instructions label on outdoor unit. This chart
selecting the 3rd position of the 3--position dip switch. For models indicates whether a correct relationship exists between system
with communicating (Infinity) systems, it must be enabled at the operating pressure and air temperature entering indoor and outdoor
User Interface. When activated, the following sequence of units. If pressure and temperature do not match on chart, system
operation will occur. Reversing valve will energize and refrigerant charge may not be correct. Do not use chart to adjust
compressor will turn off for 30 seconds, then turn back on to refrigerant charge.
complete defrost. At the end of the defrost cycle, the reversing NOTE: In heating mode, check refrigerant charge only when
valve de--energizes, compressor will turn off for another 30
pressures are stable. If in doubt, remove charge and weigh in
seconds, and the fan will turn off for 40 seconds, before starting in
correct refrigerant charge.
the heating mode.
NOTE: When charging is necessary during heating season, charge
Liquid--Line Solenoid Accessory must be weighed in accordance with unit rating plate, ±0.6 oz./ft.
In heat pump long--line applications, a liquid--line solenoid is of 3/8--in. liquid--line above or below 15 ft., respectively.
required to control refrigerant migration in the heating mode. The
EXAMPLE:
solenoid should be installed near the outdoor unit with the arrow
facing the outdoor unit. This is the direction of flow control. See To calculate additional charge required for a 25--ft. line set:
application manual for long--line application details. 25 ft. -- 15 ft. = 10 ft. X 0.6 oz./ft. = 6 oz. of additional charge.
Accessory Liquid Solenoid with Infinity Communicating
Control:
When using the Infinity Control, the liquid--line solenoid output is
provided at the Y1 connection. Connect the solenoid as shown in
the wiring label diagram. This is a 24vac output that is energized
whenever the compressor is energized. It closes, in the compressor
46
SYSTEM FUNCTIONS AND SEQUENCE OF OPERATION
The outdoor unit control system has special functions. The Utility Interface With Infinity Control
following is an overview of the two--stage control functions:
The utility curtailment relay should be wired between R and Y2
Cooling and Heating Operation connections on the control board for Infinity Communicating
25HNA6/24ANA7 and 25HNA9/24ANA1 (with serial numbers systems only (see Fig. 41.) This input allows a power utility device
starting with 3809 and later) utilize either a standard indoor to interrupt compressor operation during peak load periods. When
thermostat or Infinity Communication User Interface. the utility sends a signal to shut the system down, the User
25HNA9/24ANA1 with serial numbers starting with 3709 and Interface will display, “Curtailment Active”.
prior, utilize an Infinity communicating User Interface only. With a One Minute Stage Change Time Delay on
call for first stage cooling, the outdoor fan, reversing valve, and 25HNA6/24ANA7 Models
low stage compressor are energized. If low--stage cannot satisfy
cooling demand, high--stage cooling is energized by the second When compressor changes stages from high to low or low to high,
stage of indoor thermostat or User Interface. After second stage is there is a 1--minute time delay before compressor restarts. The
satisfied, the unit returns to low--stage operation until first stage is outdoor fan motor remains running.
satisfied or until second stage is required again. When both first Compressor Operation on 25HNA6/24ANA7
stage and second stage cooling are satisfied, the compressor will Models
shut off. The reversing valve will remain energized until the control
board power is removed or a call for heating in initiated. With a These units contain a Bristol 2--stage reciprocating compressor.
call for heating, the outdoor fan and compressor are energized. The When the compressor operates in high stage operation, the
compressor will operate in high or low stage operation, as needed compressor motor rotates clockwise. Both the lower and upper
to meet the heating demand. When the heating demand is satisfied, pistons are eccentric with the rotating crankshaft and both
the compressor and fan will shut off. The reversing valve is compress refrigerant.
de--energized in the heating mode. When the compressor operates in low stage operation, the
NOTE: When two--stage unit is operating at low--stage, system compressor motor reverses direction (rotates counterclockwise).
The lower piston becomes idle and the upper piston compresses
vapor (suction) pressure will be higher than a standard single--stage
refrigerant. The start and run windings are reversed.
system or high--stage operation.
NOTE: Outdoor fan motor will continue to operate for one minute Crankcase Heater Operation
after compressor shuts off, when outdoor ambient is greater than or The two--stage reciprocating compressor does not have a
equal to 100°F. This reduces pressure differential for easier starting replaceable CCH available. It is recommended to disconnect,
on next cycle. electronically, the faulty CCH and add a belly band style CCH
should a CCH failure be determined.
NOTE: On 25HNA6/24ANA7 models, if unit has not operated
within the past 12 hours, or following a unit power--up, upon the Compressor Operation on 25HNA9/24ANA1
next thermostat high-- or low--stage demand, unit operates for a Models:
minimum of 5 minutes in high--stage. The basic scroll design has been modified with the addition of an
On 25HNA6/24ANA7 models with non--communicating internal unloading mechanism that opens a bypass port in the first
(non--Infinity) systems, with first stage of cooling, Y1 and O are compression pocket, effectively reducing the displacement of the
powered on; and with second stage of cooling, Y1, Y2, and O are scroll. The opening and closing of the bypass port is controlled by
on. For these systems, with first stage of heating Y1 is on and for an internal electrically operated solenoid.
second stage of heating, Y1 and Y2 are on. When the reversing The modulated scroll uses a single step of unloading to go from
valve is energized, O is powered on. full capacity to approximately 67% capacity. A single speed, high
Communication and Status Function Lights For efficiency motor continues to run while the scroll modulates
between the two capacity steps. Modulation is achieved by venting
Infinity Control only, Green communications
a portion of the gas in the first suction pocket back to the low side
(COMM) Light of the compressor, thereby reducing the effective displacement of
A green LED (COMM light) on the outdoor board indicates the compressor. Full capacity is achieved by blocking these vents,
successful communication with the other system products. The thus increasing the displacement to 100%. A DC solenoid in the
green LED will remain OFF until communication is established. compressor controlled by a rectified 24 volt AC signal in the
Once a valid command is received, the green LED will turn ON external solenoid plug moves the slider ring that covers and
continuously. If no communication is received within 2 minutes, uncovers these vents. The vent covers are arranged in such a
the LED will be turned OFF until the next valid communication. manner that the compressor operates at approximately 67%
Amber Status Light capacity when the solenoid is not energized and 100% capacity
when the solenoid is energized.
An amber colored STATUS light is used to display the operation
mode and fault codes as specified in the troubleshooting section. The loading and unloading of the two step scroll is done “on the
See Table 17 for codes and definitions. fly” without shutting off the motor between steps.
NOTE: Only one code will be displayed on the outdoor unit NOTE: 67% compressor capacity translates to approximately 80%
control board (the most recent, with the highest priority). cooling or heating capacity at the indoor coil. The compressor will
always start unloaded and stay unloaded for five seconds even
when the thermostat is calling for high stage.
47
Fan Motor Outdoor Fan Motor Operation
Fan motor rotates the fan blade that either draws or blows air There are two different types of motors used in the Infinity 2--stage
through outdoor coil to exchange heat between refrigerant and air. outdoor units. The 25HNA6 models use a PSC type fan motor, and
Motors are totally enclosed to increase reliability. This also the speed does not change between high and low speed operation.
eliminates need for rain shield. On 25HNA9 models, an ECM fan motor is used to achieve higher
efficiency ratings of the system. The outdoor unit control energizes
! WARNING outdoor fan anytime compressor is operating, except for defrost or
low--ambient cooling. The outdoor fan remains energized if a
ELECTRICAL SHOCK HAZARD pressure switch or compressor overload should open. The outdoor
fan motor will continue to operate for one minute after the
Failure to follow this warning could result in personal compressor shuts off when the outdoor ambient is greater than or
injury or death. equal to 100°F/37.7°C. This reduces pressure differential for easier
Turn off all power to unit before servicing or replacing fan starting on next cycle. On 25HNA6/24ANA7 models, the outdoor
motor. Be sure unit main power switch is turned off. fan remains energized during the 1--minute compressor staging
time delay.
The bearings are permanently lubricated; therefore, no oil ports are On 25HNA6/24ANA7 models, the outdoor fan motor is a PSC
provided. type. A fan relay on the control board turns the fan off and on by
For suspected electrical failures, check for loose or faulty electrical opening and closing a high voltage circuit to the motor. It does not
connections, or defective fan--motor capacitor. Fan motor is change speeds between low and high stage operation.
equipped with thermal overload device in motor windings which On 25HNA9/24ANA1 models, the outdoor fan is an ECM type.
may open under adverse operating conditions. Allow time for The motor control is continuously powered with high voltage. The
motor to cool so device can reset. Further checking of motor can be motor speed is determined by electrical pulses provided by the
done with an ohmmeter. Set scale on R X 1 position; check for PWM outputs on the control board. The ECM motor RPM adjusts
continuity between three leads. Replace motors that show an open to outdoor conditions as described in Table 15. The PWM output
circuit in any of the windings. Place 1 lead of ohmmeter on each can be measured with a volt meter set to DC volts.
motor lead. At same time, place other ohmmeter lead on motor case In low ambient cooling (below 55°F/12.7°C), the control board
(ground). Replace any motor that shows resistance to ground, signs cycles the fan off and on.
of arcing, burning, or overheating.
Table 15—Outdoor Fan Motor PWM
Located above the compressor is a single--speed fan motor and fan.
Outdoor Temp (DC volts, Tolerance +/-- 2%)
The 24ANA1/25HNA9 air conditioner and heat pump models use
Low & High
the ECM variable speed fan motor. Low Stage High Stage
Model Stage
(OAT≤104_F / 40_C) (OAT≤104_F / 40_C)
The outdoor Integral Control Motor (ECM), is a variable--speed (OAT>104_F / 40_C)
motor which operates from 450 to 850 rpm. The motor is a dc 25HNA924 8.72 9.35 11.9
permanent magnet--type motor with the electronic controls 25HNA936 9.06 10.23 11.9
integrated into its rear cover. The control package includes a small 25HNA948 9.91 11.04 11.9
diode bridge, capacitors, and power switching devices. It converts 25HNA960 10.83 11.7 11.9
ac to dc power and switches the dc power to the motor windings on
and off at various rates to control the motor speed. The speed at 24ANA124 9.57 10.88 11.90
which the motor windings are thus commutated is determined by a 24ANA136 9.06 10.23 11.90
pulse width modulated (PWM) signal which is received from the 24ANA148 9.91 11.04 11.90
control board on the motor control lines. 24ANA160 10.83 11.70 11.90
NOTE: For 25HNA9 models in low---ambient cooling, the PWM output for
The PWM signal is created by turning a DC signal on and off once both high --- and low---stage equals the value for low---stage
within a given period of time. The signal on time relative to the operation below 55_F (12.8_C).
signal total period defines the percent of the PWM. For example, if ECM Fan Motor Troubleshooting
the period is 5 sec and the control power is turned on for 1 sec then If the outdoor fan motor fails to start and run:
off, the signal will remain off for 4 sec before turning on again to
start the next cycle. The PWM is called a 20 percent duty cycle S Check the high--voltage supply. The unit need not be
signal. If the on time is increased to 4 sec of the 5 sec period, the running to check high voltage, but the power must be on.
PWM is called an 80 percent duty cycle. The ECM reads the PWM S If the 230vac is present, use Table 15 to check for proper
signal and increases the motor speed linearly from minimum speed control voltage output to the fan motor from the control
to maximum speed with the percent duty cycle value of the board. The control board sends DC voltage signals to the
supplied PWM signal. motor through the terminals labeled PWM1 and PWM2
Set a voltmeter on a DC voltage scale and check across
these terminals.
S First check voltage with the motor disconnected. If no
control voltage is present, check control--board
connections. If connections are good, replace the control
board.
S If voltage is present, reconnect the motor and check
again. Shut down the unit to reconnect the motor and
restart the unit to complete this troubleshooting
procedure. If control voltage is no longer present or
motor fails to respond, check motor connections.
S If connections are good, replace the motor.
48
Time Delays Thermistors
The unit time delays include: Outdoor Ambient Thermistor
S Five minute time delay to start cooling or heating The Puronr two--speed air conditioner and heat pump units have
operation when there is a call from the thermostat or user an outdoor ambient air thermistor. The control board must know
interface. To bypass this feature, momentarily short and the outdoor air temperature so it can activate various functions.
release Forced Defrost pins. These functions include:
S Five minute compressor re--cycle delay on return from a S Activating the compressor crankcase heater when ever
brown--out condition. the outdoor unit is in the off cycle.
S Two minute time delay to return to standby operation The fan motor speed changes for both air conditioner
S
from last valid communication (with Infinity only). and heat pump on the ECM equipped units.
S One minute time delay of outdoor fan at termination of Outdoor Coil Thermistor(OCT)
cooling mode when outdoor ambient is greater than or The coil or defrost thermistor is the same thermistor used to
equal to 100_F. monitor outdoor air temperature. The control board must know the
coil temperature so it can activate various functions. These
S Fifteen second delay at termination of defrost before the
functions include:
auxiliary heat (W1) is de--energized.
S Frost sensing on heat pumps
S Twenty second delay at termination of defrost before the
outdoor fan is energized. S Coil--vs--Ambient temperature relationship
S Thirty second compressor delay when quiet shift Low ambient cooling operation
S
enabled. Thermistor Curve
S On 25HCB6, 25HPA6, 25HNA6 models there is a 1 The resistance vs. temperature chart enables the service technicians
minute time delay between staging from low to high and to check thermistor resistance, regardless of the temperature.
from high to low capacity. On 25HNA9 models there is For example, at a 60_F temperature, thermistor resistance should
no delay; the compressor will change from low to high be around 16,000 Ohms. (See Fig. 34.)
and from high to low capacity “on the fly” to meet the We will talk about the thermistor in more detail when we review
demand. the control board fault codes.
Pressure Switches
The Puronr two--stage air conditioner contains two pressure THERMISTOR CURVE
switches to prevent system operation if the pressures get 90
excessively high or low. The air conditioner low pressure switch in
80
the suction line opens at 50 PSI and closes at 95 PSI. The high
RESISTANCE (KOHMS)
pressure switch opens at 670 PSI and closes at 470 PSI. Both 70
pressure switch settings are considerably higher than on 60
comparably sized R--22 units. The high and low pressure switches
50
can be identified by their pink stripe on the switch’s electrical
wires. 40
The Puronr two--stage heat pump contains a loss of charge switch 30
in the suction line on 25HNB6 and 25HNA9, and liquid line on 20
25HCB6 and 25HPA6 which opens at 23 PSI and closes at 55 PSI.
See troubleshooting section for sequence when a pressure switch 10
trip occurs. 0
0 20 40 60 80 100 120
Muffler, Accumulator, Reversing Valve (RVS) (-17.77) (-6.67) (4.44) (15.56) (26.67) (37.78) (48.89)
The Puronr two--stage air conditioners and heat pumps have a TEMPERATURE °F (°C)
compressor discharge line muffler, to dampen sound pressure
pulsations. A08054
The Puronr two--stage heat pumps have a specifically designed Fig. 34 – Resistance Values Versus Temperature
reversing valve, for Puronr application and an accumulator for
storing excess liquid refrigerant during the heating mode to prevent
damaging flood--back.
49
CONTROL BOX
Contactor And Capacitor Start Circuit Sequence of Operation --
Removal of the information plate exposes the control components. 24ANA7 & 25HNA6
Both air conditioner and heat pump control boxes will appear to be On a call for high-- or low--stage compressor operation, the start
nearly identical. There are two contactors, two capacitors, a control relay is closed by the control board through the Vs, Vr, and L2
board and a compressor start assist. The contactors are identical to terminals. This puts the start capacitor in the circuit. Compressor
those used in the standard single speed units. One controls low voltage is sensed on the VR and VS terminals throughout the
capacity operation and the second controls high speed. The process. As the compressor comes up to speed, the control board
capacitors also are similar to those used in standard single speed senses the change in voltage across VR and VS, and opens the start
units. You have a fan capacitor for the outdoor fan motor, and a run relay at the appropriate voltage. The control is programmed with
capacitor for the compressor motor. The control board, start the parameters for opening the start circuit. The voltage will be
capacitor, and start relay control the starting of the compressor. different for high-- and low--stage, and for different unit sizes.
Always replace these devices with the Factory Approved Since the same control board is used in all 2--stage units, the model
Components. plug determines the start circuit voltage.
Incoming Power Troubleshooting 24ANA7 & 25HNA6 Start
Incoming power is attached to the two power wire stripped leads. Circuit:
A ground lug is also provided. Outdoor unit should always be
If starting problems are encountered, the control board will flash
grounded through the ground lug to the unit disconnect and from
fault codes to help indicate where the problem was encountered.
the disconnect to the electrical fuse box. Failure to do so can cause
See Table 17 for appropriate actions by active fault code.
serious injury or death.
S First check that the model plug is correct for the unit
Start Circuit -- 24ANA7 & 25HNA6 model and size, and that it is installed properly
These models use the same Bristol TS reciprocating compressor
that was used in previous 2--stage Puron units. A start circuit is
needed so that the reciprocating compressor will start against
elevated head pressure. The start circuit these units use is different
from previous units. The start relay is a normally open type, and is
controlled by the circuit board instead of directly sensing the
compressor voltage.
Fig. 35 – Performance and Infinity Series Control Box Identification
50
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 initial power up, the unit will operate according to the last valid
Troubleshooting (HK38EA003, 008, 010, 015) temporarily.
circuit boards. Pressure Switch Protection
The Infinity Series outdoor units all use the same control board. A The outdoor unit is equipped with high-- and low--pressure
model plug is used to identify the system type, and set the switches. If the control senses the opening of a high-- or
operating parameters for airflow, start circuit timing etc. (see Model low--pressure switch, it will respond as follows:
Plug section) There were two part number changes to this board
early in 2006 due to expansion of the Infinity split system product 1. De--energize the appropriate compressor contactor.
line, and expansion of the Infinity Small Packaged Product (SPP) 2. Keep the outdoor fan operating for 15 minutes.
line. This circuit board is used in both Infinity split system and 3. Display the appropriate fault code (see Table 17).
Infinity SPP systems. 4. After a 15 minute delay, if there is a call for cooling or
Replacement boards may have a different part number from the heating and LPS or HPS is reset, the appropriate
original board. A newer board will always be backward compatible compressor contactor is energized.
to previous units if it is superseded at RCD. Old boards are not 5. If LPS or HPS has not closed after a 15 minute delay, the
always forward compatible due to new functions, or software outdoor fan is turned off. If the open switch closes anytime
changes made to resolve field issues. after the 15 minute delay, then resume operation with a call
Systems Communication Failure for cooling or heating.
If communication with the Infinity control is lost with the User 6. If LPS or HPS trips 3 consecutive cycles, the unit operation
Interface, the control will flash the appropriate fault code. (See is locked out for 4 hours.
Table 17.) Check the wiring to the UI and the indoor and outdoor 7. In the event of a high--pressure switch trip or high--pressure
units. lockout, check the refrigerant charge, outdoor fan operation,
Model Plug and outdoor coil (in cooling) for airflow restrictions, or
indoor airflow in heating.
Each control board contains a model plug. The correct model plug
must be installed for or the system to operate properly. (See Table 8. In the event of a low--pressure switch trip or low--pressure
14.) lockout, check the refrigerant charge and indoor airflow
(cooling) and outdoor fan operation and outdoor coil in
The model plug is used to identify the type and size of unit to the heating.
control. On 25HNA6 models, the model plug is also used to
determine the start sequence timing for each individual model. Control Fault
On new units, the model and serial numbers are input into the If the outdoor unit control board has failed, the control will flash
board’s memory at the factory. If a model plug is lost or missing at the appropriate fault code (see Table 17). The control board should
initial installation, the unit will operate according to the be replaced.
information input at the factory and the appropriate error code will Brown--Out Protection
flash temporarily. An RCD replacement board contains no model If the line voltage is less than 187v for at least 4 seconds, the
and serial information. If the factory control board fails, the model appropriate compressor contactor and fan relay are de--energized.
plug must be transferred from the original board to the replacement Compressor and fan operation are not allowed until voltage is a
board for the unit to operate. minimum of 190v. The control will flash the appropriate fault code
NOTE: The model plug takes priority over factory model (see Table 17).
51
230v Brown--Out Protection Defeated 25HNA9 Compressor Thermal Cutout
The brownout feature can be defeated if needed for severe noisy If the control senses the compressor voltage after start--up and is
power conditions. This defeat should always be a last resort to then absent for 10 consecutive seconds while cooling or heating
solving the problem. Defeat is available on the User Interface demand exists, the thermal protector is open. The control
setup screen (available with SYSTXBBUID01--C UI) or can be de--energizes the compressor contactor for 15 minutes, but
initiated through the forced defrost pins for non--communicating continues to operate the outdoor fan. The control Status LED will
systems as follows: flash the appropriate code shown in Table 17. After 15 minutes,
The brownout toggle is accomplished by shorting the defrost pins with a call for low or high stage cooling or heating, the compressor
from power up with the OAT and OCT sensor connector removed. contactor is energized. If the thermal protector has not re--set, the
After 3 seconds, the status of the force defrost short and the outdoor fan is turned off. If the call for cooling or heating
OAT/OCT as open will be checked. If correct, then the brownout continues, the control will energize the compressor contactor every
will be toggled. 15 minutes. If the thermal protector closes, (at the next 15 minute
interval check) the unit will resume operation.
S Status code 6 shows the brownout is disabled.
If the thermal cutout trips for three consecutive cycles, then unit
S Status code 5 shows the brownout is active. operation is locked out for 4 hours and the appropriate fault code is
After the brownout defeat is set, power down and reinstall the displayed.
OAT/OCT sensor and remove the short from the forced defrost Low or High Contactor Open (25HNA6 models) /
pins. As long as the short on the forced defrost remains, the OAT
and OCT faults will not be cleared. The code will continue to be No 230V at Compressor Contractor (25HNA9
flashed. models)
The control is shipped with the brownout active. The change in If the compressor voltage is not sensed when the compressor
status is remembered until toggled to a new status. A power should be starting, the appropriate contactor may be stuck open or
down/power up sequence will not reset the status. It may be there is a wiring error. The control will flash the appropriate fault
necessary to do the toggle twice to cycle to the desired state of the code. Check the contactor and control box wiring.
defeat. 25HNA6 Models Only -- Compressor Start
230V Line (Power Disconnect) Detection Detection on Models with Bristol Compressors
If there is no 230v at the compressor contactor(s) when the indoor Only
unit is powered and cooling or heating demand exists, the
In low stage, if the specified start voltage at VR terminal is not
appropriate fault code is displayed. Verify the disconnect is closed
achieved, the start relay is de--energized after 1 second and the
and 230v wiring is connected to the unit.
control will flash the appropriate fault code.
Compressor Voltage Sensing In high stage, if the specified start voltage at VS terminal is not
The control board input terminals labeled VS, VR and L2 on achieved, the start relay is de--energized after 1 second and the
25HNA6/24ANA7 models and VS and L2 on 25HNA9/24ANA1 control will flash the appropriate fault code.
models (see Fig. 36) are used to detect compressor voltage status If the specified start voltage is not achieved for 3 consecutive low
and alert the user of potential problems. The control continuously stage starts, low stage operation is locked out for 30 minutes. If the
monitors the high voltage on the run capacitor of the compressor specified start voltage is not achieved for 3 consecutive high stage
motor. Voltage should be present any time the compressor starts, high stage operation is locked out for 30 minutes. The
contactor is energized and voltage should not be present when the control will flash the appropriate fault code.
contactor is de--energized.
Troubleshooting 25HNA6 units for proper
Contactor Shorted Detection switching between low & high stages
If there is compressor voltage sensed when there is no demand for
Check the suction and liquid pressures at the service valves.
compressor operation, the contactor may be stuck closed or there
Suction pressure should be reduced by 5--10% when switching
may be a wiring error. The control will flash the appropriate fault
from low to high capacity. There should be a 10--20% increase in
code.
liquid pressure when switching from low to high capacity.
25HNA6 Models -- Compressor Thermal Cutout Compressor current should increase 100--250% when switching
The control senses the compressor voltage at VR and VS. When from low to high stage.
starting or running, a phase difference of the voltages on the inputs Troubleshooting 25HNA9 units for proper
will indicate the thermal protector is closed. If the phase difference
switching between low & high stages
is 5_ or less for 10 seconds, the internal protector is open. The
control de--energizes the appropriate compressor contactor for 15 Check the suction pressures at the service valves. Suction pressure
minutes, but continues to operate the outdoor fan. The control should be reduced by 3--10% when switching from low to high
Status LED will flash the appropriate code shown in Table 17. capacity.
After 15 minutes, with a call for low or high stage cooling or NOTE: The liquid pressures are very similar between low and
heating, the appropriate compressor contactor is energized. If the high stage operation, so liquid pressure should not be used for
thermal protector has not re--set, the outdoor fan is turned off. If troubleshooting.
the call for cooling or heating continues, the control will energize Compressor current should increase 20--45% when switching from
the compressor contactor every 15 minutes. If the thermal low to high stage. The compressor solenoid when energized in
protector closes, (at the next 15 minute interval check) the unit will high stage, should measure 24vac.
resume operation.
When the compressor is operating in low stage the 24v DC
If the thermal cutout trips for three consecutive cycles, then unit compressor solenoid coil is de--energized. When the compressor is
operation is locked out for 4 hours and the appropriate fault code is operating in high stage, the 24v DC solenoid coil is energized. The
displayed. solenoid plug harness that is connected to the compressor HAS an
internal rectifier that converts the 24v DC signal to 24v AC. DO
NOT INSTALL A PLUG WITHOUT AN INTERNAL
RECTIFIER.
52
Unloader Test Procedure Thermistor Sensor Comparison
The unloader is the compressor internal mechanism, controlled by The control continuously monitors and compares the outdoor air
the DC solenoid, that modulates between high and low stage. If it temperature sensor and outdoor coil temperature sensor to ensure
is suspected that the unloader is not working, the following proper operating conditions. The comparison is:
methods may be used to verify operation. S In cooling if the outdoor air sensor indicates ≥ 10_F
1. Operate the system and measure compressor amperage. warmer than the coil sensor (or) the outdoor air sensor
Cycle the unloader on and off at 30 second plus intervals at indicates ≥ 20_F cooler than the coil sensor, the sensors
the UI (from low to high stage and back to low stage). Wait are out of range.
5 seconds after staging to high before taking a reading. The
S In heating if the outdoor air sensor indicates ≥ 35_F
compressor amperage should go up or down at least 20
percent. warmer than the coil sensor (or) the outdoor air sensor
indicates ≥ 10_F cooler than the coil sensor, the sensors
2. If the expected result is not achieved, remove the solenoid are out of range.
plug from the compressor and with the unit running and the
UI calling for high stage, test the voltage output at the plug If the sensors are out of range, the control will flash the appropriate
with a DC voltmeter. The reading should be 4 to 18 volts. fault code as shown in Table 17.
3. If the correct DC voltage is at the control circuit molded The thermistor comparison is not performed during low ambient
plug, measure the compressor unloader coil resistance. The cooling or defrost operation.
resistance should be 32 to 60 ohms depending on Failed Thermistor Default Operation
compressor temperature. If the coil resistance is infinity, Factory defaults have been provided in the event of failure of
much lower than 32 ohms, or is grounded, the compressor outdoor air thermistor (OAT) and/or outdoor coil thermistor
must be replaced. (OCT).
Temperature Thermistors If the OAT sensor should fail, low ambient cooling will not be
Thermistors are electronic devices which sense temperature. As the allowed and the one--minute outdoor fan off delay will not occur.
temperature increases, the resistance decreases. Thermistors are Defrost will be initiated based on coil temperature and time.
used to sense outdoor air (OAT) and coil temperature (OCT). If the OCT sensor should fail, low ambient cooling will not be
Refer to Fig. 34 for resistance values versus temperature. allowed. Defrost will occur at each time interval during heating
If the outdoor air or coil thermistor should fail, the control will operation, but will terminate after 5 minutes.
flash the appropriate fault code. (See Table 17.) If there is a thermistor out of range error, defrost will occur at each
IMPORTANT: The outdoor air thermistor and coil thermistor time interval during heating operation, but will terminate after 5
should be factory mounted in the final locations. Check to minutes.
ensure thermistors are mounted properly per Fig. 37 and Fig. Count the number of short and long flashes to determine the
38. appropriate flash code. Table 17 gives possible causes and actions
related to each error.
OAT Thermistor must be locked in

place with spherical nib end facing to-
wards the front of the control box OCT Thermistor
must be secured
tight on stub tube.
Fig. 37 – Outdoor Air Thermistor (OAT) Attachment

Fig. 38 – Outdoor Coil Thermistor (OCT) Attachment
Table 16—Two--Stage Compressor Resistances

(Winding Resistance at 70_F±20_)
Winding 25HNA624 25HNA636 25HNA648 25HNA660

Start (S-- C) 2.74 1.98 1.55 0.74
Run (R-- C) 0.80 0.75 0.48 0.36
25HCB624 25HCB636 25HCB648 25HCB660

Winding 25HPA624 25HPA636 25HPA648 25HPA660
25HNA924 25HNA936 25HNA948 25HNA960
Start (S-- C) 1.40 1.29 1.52 0.60
Run (R-- C) 1.32 0.89 0.64 0.49
53
Status Codes
Table 17 shows the status codes flashed by the amber status light. The short flash is 0.25 seconds ON and the long flash is 1.0 second
Most system problems can be diagnosed by reading the status code ON. Time between flashes is 0.25 seconds. Time between short
as flashed by the amber status light on the control board. flash and first long flash is 1.0 second. Time between code
The codes are flashed by a series of short and long flashes of the repeating is 2.5 seconds with LED OFF.
status light. The short flashes indicate the first digit in the status EXAMPLE:
code, followed by long flashes indicating the second digit of the 3 short flashes followed by 2 long flashes indicates a 32 code.
error code. Table 17 shows this to be low pressure switch open.
Table 17—TROUBLESHOOTING
AMBER
OPERATION FAULT LED FLASH POSSIBLE CAUSE AND ACTION
CODE
Standby – no call for unit opera- On solid,
None Normal operation
tion no flash
Standard Thermostat
Emergency Mode --- Model Rapid, Unit being controlled by standard thermostat inputs instead of Infinity Con-
Control
25HNA9/24ANA1 with serial num- continuous trol. Only high stage operation is available. This operating mode should be
(25HNA9/24ANA1
ber 3709 and prior. flashing used in emergency situations only.
only)
Low Stage Cool/Heat Operation None 1, pause Normal operation
High Stage Cool/Heat Operation None 2, pause Normal operation
System Communica- Communication with User Interface lost. Check wiring to UI, indoor and
16
tions Failure outdoor units
Control does not detect a model plug or detects an invalid model plug. Unit
Invalid Model Plug 25
will not operate without correct model plug.
High Pressure Switch High ---pressure switch trip. Check refrigerant charge, outdoor fan operation
31*
Open and coils for airflow restrictions.
Low Pressure Switch
32* Low---pressure switch trip. Check refrigerant charge and indoor air flow.
Open
Control Fault 45 Outdoor unit control board has failed. Control board needs to be replaced.
Line voltage < 187v for at least 4 seconds. Compressor and fan operation
Brown Out (230v) 46
not allowed until voltage>190v. Verify line voltage.
No 230v at Unit There is no 230v at the contactor when indoor unit is powered and cooling/
Measured at L1 and 47 heating demand exists. Verify the disconnect is closed and 230v wiring is
L2 on circuit board connected to the unit.
Outdoor Air Temp Outdoor air sensor not reading or out of range. Ohm out sensor and check
53
Sensor Fault wiring.
Outdoor Coil
55 Coil sensor not reading or out of range. Ohm out sensor and check wiring.
Sensor Fault
Thermistors out of Improper relationship between coil sensor and outdoor air sensor. Ohm out
56
range sensors and check wiring.
Compressor operation detected then disappears while low stage demand
Low Stage
71* exists. Possible causes are internal compressor overload trip or start relay
Thermal Cutout
and capacitor held in circuit too long (if installed).
Compressor operation detected then disappears while high stage demand
High Stage
Thermal Cutout
Compressor voltage sensed when no demand for compressor operation
Contactor Shorted 73*
exists. Contactor may be stuck closed or there is a wiring error.
No 230V at
Compressor voltage not sensed when compressor should be starting. Con-
Compressor 74
tactor may be stuck open or there is a wiring error.
(25HNA9 Only)
Low Stage Did Not
Specified start voltage at VR terminal was not achieved in low stage. Start
Start 75
relay was de ---energized after 1 second.
(25HNA6 Only)
Low Stage Did Not For 3 consecutive low stage starts, the specified start voltage at VR terminal
Start 3 times 76 was not achieved & start relay was de ---energized. Low stage locked out for
(25HNA6Only) 30 minutes.
High Stage Did Not
Specified start voltage at VS terminal was not achieved in high stage. Start
Start 77
relay was de ---energized after 1 second.
(25HNA6 Only)
High Stage Did Not For 3 consecutive high stage starts, the specified start voltage at VS terminal
Start 3 times 78 was not achieved & start relay was de ---energized. High stage locked out for
(25HNA6 Only) 30 minutes.
Low Stage Thermal cutout occurs in three consecutive low/high stage cycles. Low
81
Thermal Lockout stage locked out for 4 hours or until 24v power recycled.
High Stage Thermal cutout occurs in three consecutive high/low stage cycles. High
82
Low---Pressure Lock- Low pressure switch trip has occurred during 3 consecutive cycles. Unit
83
out operation locked out for 4 hours or until 24v power recycled.
High ---Pressure High pressure switch trip has occurred during 3 consecutive cycles. Unit
84
Lockout operation locked out for 4 hours or until 24v power recycled.
Low Contactor Open Compressor voltage not sensed when compressor should be starting. Low
85
(25HNA6 Only) stage contactor may be stuck open or there is a wiring error.
High Contactor Open Compressor voltage not sensed when compressor should be starting. High
87
(25HNA6 Only) stage contactor may be stuck open or there is a wiring error.
*Sequence: Compressor contactor is de ---energized and outdoor fan is energized for up to 15 minutes. If demand still exists, control will energize compressor
contactor after 15 minute delay. If fault is cleared, unit will resume operation. If fault still exists, fan shuts off, and error code continues to flash. Control will attempt
re ---start every 15 minutes. Cycling low voltage defeats the 15 minute delay.
54
FAN 2 STAGE TWO-STAGE
THERMIDISTAT (TSTAT) VARIABLE SPEED
THERMIDISTAT COIL HEAT PUMP
FURNACE
O O
Y1 Y1
RVS/Heat Stage 2 O/B W2
Heat Stage 1 W/W1 W1 W1
REMOVE J2
JUMPER FOR
Compressor Low Y1 W2 HEAT STAGING
Compressor High Y/Y2 Y/Y2 Y2 W1
Fan G G
24VAC Hot Heating Rh R R
REMOVE J1 FOR
24VAC Hot Cooling Rc DEHUMIDIFY
DH MODES
Dry Contact 1 D1
C C
Dry Contact 2 D2
24VAC Common C
Humidify HUM
Humidifier Solenoid
Outdoor Air Temp OAT Valve *
Remote Room Sensor RRS Outdoor Sensor *
OAT/RRS Com OAT/RRS Remote Room
Sensor *
A08055 A08090
Fig. 39 – Edge Thermidistat Models TP-- PRH-- 01 or TP-- NRH-- 01) Fig. 40 – Thermidistat Model TSTATCCPRH01-- B with Variable
Wiring with 25HCB6, 25HPA6, 25HNA6, 25HNA9 Speed Furnace and 25HCB6, 25HPA6, 25HNA6, 25HNA9
Two-- Stage Heat Pump (non-- communicating) Two-- Stage Heat Pump (non-- communicating)
User Interface Furnace or Fan Coil Communicating HP
D D D
C C C
B B B
A A A
OAT
R
Y
O
Humidifier
W
C
24vac C
HUM
A08091
Fig. 41 – Infinity Furnace or Fan Coil Wiring with 25HPA6, 25HNA6 OR 25HNA9 Communicating Two-- Stage HP
55
TWO--STAGE 25HNB/24ANB
Application Guidelines Model Plug
Carrier designed and tested the two--stage air conditioner and heat Each control board contains a model plug. The correct model plug
pump products with Puron refrigerant to operate at a minimum must be installed in order for the system to operate properly. (See
outdoor operating ambient in cooling mode at 55_F without low Table 18.)
ambient cooling enabled and the maximum outdoor operating The model plug is used to identify the type and size of unit to the
ambient in cooling is 125_F/51.6_C. On Infinity communicating control. On 25HNB6 models, the model plug is also used to
systems, only low ambient cooling is available to 0_F/--17.8_C. determine the start sequence timing for each individual model.
The maximum outdoor operating ambient in heating mode is On new units, the model and serial numbers are inputted into the
66_F/18.8_C on all heat pumps. Continuous operation in heating board’s memory at the factory. If a model plug is lost or missing at
mode is approved to --30_F/--34.4_C. Thermostat options for the initial installation, the unit will operate according to the
two stage units are as follows: information input at the factory and the appropriate error code will
S A,B,C,D four--wire connections for Infinity User flash temporarily. An RCD replacement board contains no model
Interface. and serial information. If the factory control board fails, the model
plug must be transferred from the original board to the replacement
S R,C,W,Y1,Y2, and O wire connections for standard,
non--communicating thermostat.
NOTE: The model plug takes priority over factory model
25HNB6, 25HNB9, 24ANB7, and 24ANB1 units can run, and are
matched with, User Interface (UI) communicating and
non--communicating indoor fan coils and furnaces. Only unit
combinations listed in the two--stage Product Data are
recommended. temporarily.
Line sets for two stage units are similar to the single stage units. Table 18—Model Plug Information
However, some restrictions may apply to specific combinations in PIN RESISTANCE
long line applications. Refer to the Long Line Guideline for further MODEL
MODEL (K---ohms)
PLUG
information. NUMBER
NUMBER
The Tennessee Valley Authority (TVA) requires that electric strip Pins 1---4 Pins 2---3
heat have a lockout feature. This is achieved through Carrier 25HNB624 HK70EZ041 18 91
thermostats required per above and must be used on all TVA
25HNB636 HK70EZ043 18 150
approved units.
25HNB648 HK70EZ045 18 220
The new control board in the two stage units with Puron refrigerant
25HNB660 HK70EZ047 18 360
has dip switches for defrost timing. The Infinity controls provide
these two stage units with high stage latching and Hybrid Heatt
25HNB936 HK70EZ012 5.1 180
(dual fuel) capabilities. The standard Hybrid Heatt (duel fuel)
25HNB948 HK70EZ014 5.1 270
thermostat can be used on two stage units with Bristol
reciprocating compressors only. 25HNB960 HK70EZ016 11 5.1
24ANB124 HK70EZ009 5.1 91

24ANB136 HK70EZ011 5.1 150
24ANB148 HK70EZ013 5.1 220
24ANB160 HK70EZ015 5.1 360
24ANB724 HK70EZ040 18 75
24ANB736 HK70EZ042 18 120
24ANB748 HK70EZ044 18 180
24ANB760 HK70EZ046 18 270
56
Airflow Selections for 24ANB7 / 25HNB6 / S Low pressure switch is ignored for first 3 minutes during
24ANB1 /25HNB9 Using Non--Communicating low ambient start up. After 3 minutes, if LPS trips, then
outdoor fan motor is turned off for 10 minutes, with the
(Non--Infinity) Thermostats
compressor running. If LPS closes within 10 minutes
Airflow Selection for 58CVA/58MVB Furnaces then cooling continues with the outdoor fan cycling per
The 58CVA/58MVB variable--speed furnaces provide high--and the coil temperature routine listed above for the
low--stage blower operation to match the capacities of the remainder of the cooling cycle. If the LPS does not close
compressor at high and low stages. To select the recommended within 10 minutes, then the normal LPS trip response
airflow and for adjustments to the manual switches labeled SW1--5, (shut down cooling operation and generate LPS trip
AC, and CF on the control board, refer to the furnace Installation error) will occur.
Instructions. The 58CVA/58MVB utilizes a control center that For 24ANB1/25HNB9 models, the PWM output for both high and
allows the installing technician to select the proper airflows. The low stage equals the value for low stage operation below 55_F.
HP switch determines the airflow during high--stage compressor
operation. Airflow for high-- and low--stage can be calculated at Defrost
either 350 CFM per ton or 400 CFM per ton, based on the This control offers 5 possible defrost interval times: 30, 60, 90, 120
positions of SW1--5. minutes, or AUTO.
When using communicating (Infinity) control, dipswitch With non--communicating thermostats, these are selected by dip
adjustments are not necessary on furnaces. Airflows are switches on the unit control board. With communicating
determined by Infinity Control setup. thermostats, the Infinity Control User Interface. The Infinity
Control selection overrides the control board dip switch settings.
Airflow Selection for FV4 Fan Coils for 24ANB1,
AUTO defrost adjusts the defrost interval time based on the last
24ANB7, 25HNB6, 25HNB9 Using defrost time as follows:
Non--Communicating (Non--Infinity) Thermostats
S When defrost time <3 minutes, the next defrost
The FV4 provides high-- and low--stage blower operation to match interval=120 minutes.
the capacities of compressor at high-- and low--stage. To select
recommended airflow, refer to FV4 Installation Instructions. The
S When defrost time 3--5 minutes, the next defrost
interval=90 minutes.
FV4 utilizes an Easy Select control board that allows the installing
technician to select proper airflows. For adjustments to control S When defrost time 5--7 minutes, the next defrost
board, select appropriate HP SIZE and CFM ADJUST setting. This interval=60 minutes.
fan coil has an adjustable blower off delay factory set at 90 sec for S When defrost time >7 minutes, the next defrost
high-- and low--stage blower operation. interval=30 minutes.
For other combinations of equipment consult Product Data Digest. The control board accumulates compressor run time. As the
GENERAL INFORMATION accumulated run time approaches the selected defrost interval time,
the control board monitors the coil temperature sensor for a defrost
Low Ambient Cooling demand. If a defrost demand exists, a defrost cycle will be initiated
When this unit is operating below 55_F outdoor temperature, at the end of the selected time interval. A defrost demand exists
provisions must be made for low ambient operation. when the coil temperature is at or below 32_F for 4 minutes during
Infinity Controlled low ambient cooling: the interval.
This unit is capable of low ambient cooling without a kit ONLY
65_F or 10 minutes has passed.
when using Infinity control. A low ambient kit is not required, and
the outdoor fan motor does not need to be replaced for Infinity On 25HNB6 models, defrost will occur in low-- or high--stage as
controlled low ambient operation. The Infinity Control provides an demanded by the thermostat or User Interface regardless of OAT
automatic evaporator coil freeze protection algorithm that On 25HNB9 models, when OAT is >25_F (--3.9_C), defrost will
eliminates the need for an evaporator freeze thermostat. Low occur in low-- or high--stage as demanded by the thermostat or
ambient cooling must be enabled in the User Interface set up. Fan User Interface.
may not begin to cycle until about 40_F OAT. Fan will cycle On 25HNB9 models, if OAT is ≤25_F (--3.9_C), defrost will
based on coil and outdoor air temperature. occur in high--stage only, regardless of thermostat or User Interface
Infinity controlled low ambient mode operates as follows: demand, and will terminate at 50_F (10_C) coil temperature with a
S Fan is OFF when outdoor coil temp is < (outdoor air minimum of 2.5 minutes in defrost.
temperature + 3_F) or outdoor fan has been ON for 30 If the coil temperature does not reach 32_F (0_C) within the
minutes. (Fan is turned off to allow refrigerant system to interval, the interval timer will be reset and start over.
stabilize.) S Upon initial power up the first defrost interval is
S Fan is ON when outdoor coil temp > (outdoor air defaulted to 30 minutes. Remaining intervals are at
temperature + 25_F) or outdoor coil temp > 80_F or if selected times.
outdoor fan has been OFF for 30 minutes. (Fan is turned S Defrost is only allowed to occur below 50_F (10_C)
on to allow refrigerant system to stabilize.) outdoor ambient temperature.
The outdoor fan output (ODF) will remain off for 20 seconds after
termination. This delay will allow time for the system to capture
the heat from the outdoor coil and reduce the “steam cloud” effect
that may occur on transition from defrost to the heating cycle. The
enable the fan to energize immediately at the time of termination
and 12 seconds prior to the reversing valve de--energizing, through
the User Interface setup screen available with SYSTXBBUID01--C
UI, or forced defrost pins as follows:
57
S The ODF fan delay defeat can be toggled by shorting the off mode, to prevent refrigerant migration into the unit through the
forced defrost pins for >15 seconds while in the standby liquid--line.
mode (status LED on solid). The LED will start to flash On Models with Accessory Liquid Solenoid Using a
when the toggle has taken place. Non--Communicating Thermostat:
S Status code 4 shows the fan delay defeat is active (no The liquid solenoid is connect to the Y1 and C terminal
delay) connections. The liquid solenoid closes, in the compressor off
mode, to prevent refrigerant migration into the unit through the
S Status code 3 shows that it is not active (20 second
liquid--line.
delay)
The code will continue to be displayed until after the short is CHECK CHARGE
removed. Once the short is removed, there is a 5 second wait All 25HNB6 units must be charged in high stage only.
before the code is cancelled. The code that is flashing will finish
before going back to sold LED. the control is shipped with the
ODF fan delay defeat NOT active. the change in status is
remembered until toggled to a new status. A power down / power
favorable for subcooling charging. Favorable conditions exist
up sequence will not reset the status. It may be necessary to do the
when the outdoor temperature is between 70_F and 100_F
toggle twice to cycle to the desired state of defeat.
(21.11_C and 37.78_C), and the indoor temperature is between
Defrost Hold 70_F and 80_F (21.11_C and 26.67_C). Follow the procedure
in a non--communicating system, if the thermostat becomes below:
satisfied (Y1 or Y1 and Y2) before the defrost cycle is terminated, Unit is factory charged for 15ft (4.57 m) of lineset. Adjust charge
the control will “hold” in defrost mode and finish the defrost cycle by adding or removing 0.6 oz/ft of 3/8 liquid line above or below
on the next call for heat. 15ft (4.57 m) respectively.
With communicating Infinity Control, defrost hold is not needed in For standard refrigerant line lengths (80 ft/24.38 m or less), allow
a communicating system because the User Interface will complete system to operate in cooling mode at least 15 minutes. If conditions
the defrost cycle before shutting down the system. are favorable, check system charge by subcooling method. If any
Forced Defrost adjustment is necessary, adjust charge slowly and allow system to
With non--communicating (non--Infinity) control, forced defrost operate for 15 minutes to stabilize before declaring a properly
can be initiated by manually shorting the 2--pin header labeled charged system.
FORCED DEFROST (see Fig 43) on the control board for 5 If the indoor temperature is above 80_F (26.67_C), and the
seconds then releasing. outdoor temperature is in the favorable range, adjust system charge
With communicating (Infinity) control, forced defrost is initiated by weight based on line length and allow the indoor temperature to
with the User Interface. drop to 80_F (26.67_C) before attempting to check system charge
On all models, during a Forced Defrost:
S If coil temperature is at defrost temperature of 32_F, and temperature is not in the favorable range, adjust charge for line set
outdoor air temperature is below 50_F, a full defrost length above or below 15ft (4.57 m) only. Charge level should then
sequence will occur. be appropriate for the system to achieve rated capacity. The charge
S If coil temperature or outdoor air temperature does not level could then be checked at another time when the both indoor
meet the above requirements, an abbreviated 30 second and outdoor temperatures are in a more favorable range.
defrost will occur. NOTE: If line length is beyond 80 ft (24.38 m) or greater than 20
Quiet Shift ft (6.10 m) vertical separation, See Long Line Guideline for
Quiet Shift is a field--selectable defrost mode which may eliminate
occasional noise that could be heard at the start of the defrost cycle Heating Check Chart Procedure
and restarting of the heating cycle. On models with a To check system operation during heating cycle, refer to the Heat
non--communicating system, this feature must be enabled by Pump Charging Instructions label on outdoor unit. This chart
selecting the 3rd position of the 3--position dip switch. For models indicates whether a correct relationship exists between system
with communicating (Infinity) systems, it must be enabled at the operating pressure and air temperature entering indoor and outdoor
User Interface. When activated, the following sequence of units. If pressure and temperature do not match on chart, system
operation will occur. Reversing valve will energize and refrigerant charge may not be correct. Do not use chart to adjust
compressor will turn off for 30 seconds, then turn back on to refrigerant charge.
complete defrost. At the end of the defrost cycle, the reversing
NOTE: In heating mode, check refrigerant charge only when
valve de--energizes, compressor will turn off for another 30
seconds, and the fan will turn off for 40 seconds, before starting in
the heating mode. correct refrigerant charge.
NOTE: When charging is necessary during heating season, charge
Liquid--Line Solenoid Accessory
must be weighed in accordance with unit rating plate, ±0.6 oz./ft.
In heat pump long--line applications, a liquid--line solenoid is of 3/8--in. liquid--line above or below 15 ft., respectively.
required to control refrigerant migration in the heating mode. The
EXAMPLE:
solenoid should be installed near the outdoor unit with the arrow
facing the outdoor unit. This is the direction of flow control. See To calculate additional charge required for a 25--ft. line set:
application manual for long--line application details. 25 ft. -- 15 ft. = 10 ft. X 0.6 oz./ft. = 6 oz. of additional charge.
Control:
provided at the Y1 connection. Connect the solenoid as shown in
58
SYSTEM FUNCTIONS AND
SEQUENCE OF OPERATION
The outdoor unit control system has special functions. The Compressor Operation on 25HNB9/24ANB1
following is an overview of the two--stage control functions: Models:
Cooling and Heating Operation The basic scroll design has been modified with the addition of an
The 25HNB6/24ANB7/25HNB9/24ANB1 model utilizes either a internal unloading mechanism that opens a bypass port in the first
standard 2--stage indoor thermostat or Infinity Communication compression pocket, effectively reducing the displacement of the
User Interface. With a call for first stage cooling, the outdoor fan, scroll. The opening and closing of the bypass port is controlled by
reversing valve, and low stage compressor are energized. If an internal electrically operated solenoid.
low--stage cannot satisfy cooling demand, high--stage cooling is The modulated scroll uses a single step of unloading to go from
energized by the second stage of indoor thermostat or User full capacity to approximately 67% capacity. A single speed, high
Interface. After second stage is satisfied, the unit returns to efficiency motor continues to run while the scroll modulates
low--stage operation until first stage is satisfied or until second between the two capacity steps. Modulation is achieved by venting
stage is required again. When both first stage and second stage a portion of the gas in the first suction pocket back to the low side
cooling are satisfied, the compressor will shut off. The reversing of the compressor, thereby reducing the effective displacement of
valve will remain energized until the control board power is the compressor. Full capacity is achieved by blocking these vents,
removed or a call for heating in initiated. With a call for heating, thus increasing the displacement to 100%. A DC solenoid in the
the outdoor fan and compressor are energized. The compressor will compressor controlled by a rectified 24 volt AC signal in the
operate in high or low stage operation, as needed to meet the external solenoid plug moves the slider ring that covers and
heating demand. When the heating demand is satisfied, the uncovers these vents. The vent covers are arranged in such a
compressor and fan will shut off. The reversing valve is manner that the compressor operates at approximately 67%
de--energized in the heating mode. capacity when the solenoid is not energized and 100% capacity
NOTE: When two--stage unit is operating at low--stage, system when the solenoid is energized.
vapor (suction) pressure will be higher than a standard single--stage The loading and unloading of the two step scroll is done “on the
system or high--stage operation. fly” without shutting off the motor between steps.
NOTE: Outdoor fan motor will continue to operate for one minute NOTE: 67% compressor capacity translates to approximately 80%
after compressor shuts off, when outdoor ambient is greater than or cooling or heating capacity at the indoor coil. The compressor will
equal to 100°F. This reduces pressure differential for easier starting always start unloaded and stay unloaded for five seconds even
on next cycle. when the thermostat is calling for high stage.
NOTE: If unit has not operated within the past 12 hours, or Fan Motor
following a unit power--up, upon the next thermostat high-- or
Fan motor rotates the fan blade that either draws or blows air
low--stage demand, unit operates for a minimum of 5 minutes in
through outdoor coil to exchange heat between refrigerant and air.
high--stage. Motors are totally enclosed to increase reliability. This also
On models with non--communicating (non--Infinity) systems, with eliminates need for rain shield.
first stage of cooling, Y1 and O are powered on; and with second
stage of cooling, Y1, Y2, and O are on. For these systems, with
first stage of heating Y1 is on and for second stage of heating, Y1
! WARNING
and Y2 are on. When the reversing valve is energized, O is
powered on.
Communication and Status Function Lights For or death.
Infinity Control only, Green communications Turn off all power to unit before servicing or replacing fan
(COMM) Light motor. Be sure unit main power switch is turned off.
A green LED (COMM light) on the outdoor board indicates
successful communication with the other system products. The The bearings are permanently lubricated; therefore, no oil ports are
green LED will remain OFF until communication is established. provided.
Once a valid command is received, the green LED will turn ON For suspected electrical failures, check for loose or faulty electrical
continuously. If no communication is received within 2 minutes, connections, or defective fan--motor capacitor. Fan motor is
the LED will be turned OFF until the next valid communication. equipped with thermal overload device in motor windings which
Amber Status Light may open under adverse operating conditions. Allow time for
An amber colored STATUS light is used to display the operation motor to cool so device can reset. Further checking of motor can be
mode and fault codes as specified in the troubleshooting section. done with an ohmmeter. Set scale on R X 1 position; check for
See Table 21 for codes and definitions. continuity between three leads. Replace motors that show an open
NOTE: Only one code will be displayed on the outdoor unit circuit in any of the windings. Place 1 lead of ohmmeter on each
control board (the most recent, with the highest priority). motor lead. At same time, place other ohmmeter lead on motor case
(ground). Replace any motor that shows resistance to ground, signs
Utility Interface With Infinity Control of arcing, burning, or overheating.
The utility curtailment relay should be wired between R and Y2 Located above the compressor is a single--speed fan motor and fan.
connections on the control board for Infinity Communicating The 24ANB1/25HNB9 air conditioner and heat pump models use
Systems only (see Fig. 49.) This input allows a power utility device the ECM variable speed fan motor.
to interrupt compressor operation during peak load periods. When
the utility sends a signal to shut the system down, the User
Interface will display, “Curtailment Active”.
59
The outdoor Integral Control Motor (ECM), is a variable--speed ECM Fan Motor Troubleshooting
motor which operates from 450 to 850 rpm. The motor is a dc If the outdoor fan motor fails to start and run:
permanent magnet--type motor with the electronic controls
integrated into its rear cover. The control package includes a small S Check the high--voltage supply. The unit need not be
diode bridge, capacitors, and power switching devices. It converts running to check high voltage, but the power must be on.
ac to dc power and switches the dc power to the motor windings on S If the 230vac is present, use Table 19 to check for proper
and off at various rates to control the motor speed. The speed at control voltage output to the fan motor from the control
which the motor windings are thus commutated is determined by a board. The control board sends DC voltage signals to the
pulse width modulated (PWM) signal which is received from the motor through the terminals labeled PWM1 and PWM2
control board on the motor control lines. Set a voltmeter on a DC voltage scale and check across
The PWM signal is created by turning a DC signal on and off once these terminals.
within a given period of time. The signal on time relative to the S First check voltage with the motor disconnected. If no
signal total period defines the percent of the PWM. For example, if control voltage is present, check control--board
the period is 5 sec and the control power is turned on for 1 sec then connections. If connections are good, replace the control
off, the signal will remain off for 4 sec before turning on again to board.
start the next cycle. The PWM is called a 20 percent duty cycle
signal. If the on time is increased to 4 sec of the 5 sec period, the S If voltage is present, reconnect the motor and check
PWM is called an 80 percent duty cycle. The ECM reads the PWM again. Shut down the unit to reconnect the motor and
signal and increases the motor speed linearly from minimum speed restart the unit to complete this troubleshooting
to maximum speed with the percent duty cycle value of the procedure. If control voltage is no longer present or
supplied PWM signal. motor fails to respond, check motor connections.
Outdoor Fan Motor Operation S If connections are good, replace the motor.
There are two different types of motors used in the Infinity 2--stage Time Delays
outdoor units. The 25HNB6 models use a PSC type fan motor, and The unit time delays include:
the speed does not change between high and low speed operation.
S Five minute time delay to start cooling or heating
On 25HNB9 models, an ECM fan motor is used to achieve higher
operation when there is a call from the thermostat or user
efficiency ratings of the system. The outdoor unit control energizes
interface. To bypass this feature, momentarily short and
outdoor fan anytime compressor is operating, except for defrost or
release Forced Defrost pins.
low--ambient cooling. The outdoor fan remains energized if a
pressure switch or compressor overload should open. The outdoor S Five minute compressor re--cycle delay on return from a
fan motor will continue to operate for one minute after the brown--out condition.
compressor shuts off when the outdoor ambient is greater than or S Two minute time delay to return to standby operation
equal to 100°F/37.7°C. This reduces pressure differential for easier from last valid communication (with Infinity only).
starting on next cycle. On 25HNB6/24ANB7 models, the outdoor
fan remains energized during the 1--minute compressor staging S One minute time delay of outdoor fan at termination of
time delay. cooling mode when outdoor ambient is greater than or
equal to 100_F.
On 25HNB6/24ANB7 models, the outdoor fan motor is a PSC
type. A fan relay on the control board turns the fan off and on by S Fifteen second delay at termination of defrost before the
opening and closing a high voltage circuit to the motor. It does not auxiliary heat (W1) is de--energized.
change speeds between low and high stage operation. S Twenty second delay at termination of defrost before the
On 25HNB9/24ANB1 models, the outdoor fan is an ECM type. outdoor fan is energized.
The motor control is continuously powered with high voltage. The
S Thirty second compressor delay when quiet shift
motor speed is determined by electrical pulses provided by the
enabled.
PWM outputs on the control board. The ECM motor RPM adjusts
to outdoor conditions as described in Table 19. The PWM output S On 25HCB6, 25HPA6, 25HNB6 models there is a 1
can be measured with a volt meter set to DC volts. minute time delay between staging from low to high and
In low ambient cooling (below 55°F/12.7°C), the control board from high to low capacity. On 25HNB9 models there is
cycles the fan off and on. no delay; the compressor will change from low to high
and from high to low capacity “on the fly” to meet the
Table 19—Outdoor Fan Motor PWM demand.
Outdoor Temp (DC volts, Tolerance +/-- 2%)
Low & High
Pressure Switches
Low Stage High Stage
Model
(OAT≤104_F / 40_C) (OAT≤104_F / 40_C)
Stage The Puronr two--stage air conditioner contains two pressure
(OAT>104_F / 40_C)
switches to prevent system operation if the pressures get
25HNB936 9.06 10.23 11.90 excessively high or low. The air conditioner low pressure switch in
25HNB948 9.91 11.04 11.90 the suction line opens at 50 PSI and closes at 95 PSI. The high
25HNB960 10.83 11.70 11.90 pressure switch opens at 670 PSI and closes at 470 PSI. Both
24ANB124 9.57 10.88 11.90
pressure switch settings are considerably higher than on
24ANB136 9.06 10.23 11.90
comparably sized R--22 units. The high and low pressure switches
24ANB148 9.91 11.04 11.90
can be identified by their pink stripe on the switch’s electrical
24ANB160 10.83 11.70 11.90
wires.
NOTE: For 25HNB9 models in low---ambient cooling, the PWM output for The Puronr two--stage heat pump contains a loss of charge switch
both high --- and low---stage equals the value for low---stage in the suction line on 25HNB6 and 25HNB9, and liquid line on
operation below 55_F (12.8_C).
25HCB6 and 25HPA6 which opens at 23 PSI and closes at 55 PSI.
See troubleshooting section for sequence when a pressure switch
trip occurs.
60
Muffler, Accumulator, Reversing Valve (RVS) Control Box
The Puronr two--stage air conditioners and heat pumps have a Contactor And Capacitor
compressor discharge line muffler, to dampen sound pressure Removal of the information plate exposes the control components.
pulsations. Both air conditioner and heat pump control boxes will appear to be
The Puronr two--stage heat pumps have a specifically designed nearly identical. There are two contactors, two capacitors, a control
reversing valve, for Puronr application and an accumulator for board and a compressor start assist. The contactors are identical to
storing excess liquid refrigerant during the heating mode to prevent those used in the standard single speed units. One controls low
damaging flood--back. capacity operation and the second controls high speed. The
Thermistors capacitors also are similar to those used in standard single speed
units. You have a fan capacitor for the outdoor fan motor, and a run
Outdoor Ambient Thermistor capacitor for the compressor motor. The control board, start
The Puronr two--speed air conditioner and heat pump units have capacitor, and start relay control the starting of the compressor.
an outdoor ambient air thermistor. The control board must know Always replace these devices with the Factory Approved
the outdoor air temperature so it can activate various functions. Components.
These functions include:
Incoming Power
S Activating the compressor crankcase heater when ever
Incoming power is attached to the two power wire stripped leads.
the outdoor unit is in the off cycle. A ground lug is also provided. Outdoor unit should always be
The fan motor speed changes for both air conditioner
S grounded through the ground lug to the unit disconnect and from
and heat pump on the ECM equipped units. the disconnect to the electrical fuse box. Failure to do so can cause
Outdoor Coil Thermistor(OCT) serious injury or death.
The coil or defrost thermistor is the same thermistor used to Start Circuit Sequence of Operation -- 24ANB7 & 25HNB6
monitor outdoor air temperature. The control board must know the On a call for high-- or low--stage compressor operation, the start
coil temperature so it can activate various functions. These relay is closed by the control board through the Vs, Vr, and L2
functions include: terminals. This puts the start capacitor in the circuit. Compressor
S Frost sensing on heat pumps voltage is sensed on the VR and VS terminals throughout the
process. As the compressor comes up to speed, the control board
S Coil--vs--Ambient temperature relationship senses the change in voltage across VR and VS, and opens the start
Low ambient cooling operation
S relay at the appropriate voltage. The control is programmed with
Thermistor Curve the parameters for opening the start circuit. The voltage will be
different for high-- and low--stage, and for different unit sizes.
The resistance vs. temperature chart enables the service technicians
Since the same control board is used in all 2--stage units, the model
to check thermistor resistance, regardless of the temperature.
plug determines the start circuit voltage.
For example, at a 60_F temperature, thermistor resistance should
Troubleshooting 24ANB7 & 25HNB6 Start Circuit:
be around 16,000 Ohms. (See Fig. 42.)
If starting problems are encountered, the control board will flash
We will talk about the thermistor in more detail when we review
the control board fault codes. fault codes to help indicate where the problem was encountered.
See Table 21 for appropriate actions by active fault code.
THERMISTOR CURVE S First check that the model plug is correct for the unit
model and size, and that it is installed properly
90
80
RESISTANCE (KOHMS)
70
60
50
40
30
20
10
START CAPACITOR
0 MOUNTING HOLES
0 20 40 60 80 100 120
(-17.77) (-6.67) (4.44) (15.56) (26.67) (37.78) (48.89)
TEMPERATURE °F (°C)
A08054
Fig. 42 – Resistance Values Versus Temperature
START RELAY
MOUNTING HOLE
TAB ON BOTTOM OF
START RELAY TO BE
PLACED IN THIS CORNER
A10157
Fig. 43 – Start Relay and Capacitor Mounting Locations
Evolution / Infinity in Cube Cabinet
61
MODEL
PLUG
MODEL
PLUG
UTILITY RELAY *
UTILITY SIGNAL
OPEN RELAY LLS
A06525/.A06526
TROUBLESHOOTING
Troubleshooting (HK38EA015) circuit board Pressure Switch Protection
The outdoor unit is equipped with high-- and low--pressure
The Infinity Series outdoor units all use the same control board. A
switches. If the control senses the opening of a high-- or
model plug is used to identify the system type, and set the
low--pressure switch, it will respond as follows:
operating parameters for airflow, start circuit timing etc. (see Model
Plug section) 1. De--energize the appropriate compressor contactor.
Replacement boards may have a different part number from the 2. Keep the outdoor fan operating for 15 minutes.
original board. A newer board will always be backward compatible 3. Display the appropriate fault code (see Table 21).
to previous units if it is superseded at RCD. Old boards are not 4. After a 15 minute delay, if there is a call for cooling or
always forward compatible due to new functions, or software heating and LPS or HPS is reset, the appropriate
changes made to resolve field issues. compressor contactor is energized.
Systems Communication Failure 5. If LPS or HPS has not closed after a 15 minute delay, the
If communication with the Infinity control is lost with the User outdoor fan is turned off. If the open switch closes anytime
Interface, the control will flash the appropriate fault code. (See after the 15 minute delay, then resume operation with a call
Table 21.) Check the wiring to the UI and the indoor and outdoor for cooling or heating.
units. 6. If LPS or HPS trips 3 consecutive cycles, the unit operation
is locked out for 4 hours.
Model Plug
7. In the event of a high--pressure switch trip or high--pressure
Each control board contains a model plug. The correct model plug
lockout, check the refrigerant charge, outdoor fan operation,
must be installed for or the system to operate properly. (See Table
and outdoor coil (in cooling) for airflow restrictions, or
18.)
indoor airflow in heating.
The model plug is used to identify the type and size of unit to the
8. In the event of a low--pressure switch trip or low--pressure
control. On 25HNB6 models, the model plug is also used to
lockout, check the refrigerant charge and indoor airflow
determine the start sequence timing for each individual model.
(cooling) and outdoor fan operation and outdoor coil in
On new units, the model and serial numbers are input into the heating.
board’s memory at the factory. If a model plug is lost or missing at
initial installation, the unit will operate according to the Control Fault
information input at the factory and the appropriate error code will If the outdoor unit control board has failed, the control will flash
flash temporarily. An RCD replacement board contains no model the appropriate fault code (see Table 21). The control board should
and serial information. If the factory control board fails, the model be replaced.
plug must be transferred from the original board to the replacement Brown--Out Protection
If the line voltage is less than 187v for at least 4 seconds, the
NOTE: The model plug takes priority over factory model appropriate compressor contactor and fan relay are de--energized.
information input at the factory. If the model plug is removed after Compressor and fan operation are not allowed until voltage is a
initial power up, the unit will operate according to the last valid minimum of 190v. The control will flash the appropriate fault code
model plug installed, and flash the appropriate fault code (see Table 21).
temporarily.
62
230v Brown--Out Protection Defeated 25HNB9 Compressor Thermal Cutout
The brownout feature can be defeated if needed for severe noisy If the control senses the compressor voltage after start--up and is
power conditions. This defeat should always be a last resort to then absent for 10 consecutive seconds while cooling or heating
solving the problem. Defeat is available on the User Interface demand exists, the thermal protector is open. The control
setup screen (available with SYSTXBBUID01--C UI) or can be de--energizes the compressor contactor for 15 minutes, but
initiated through the forced defrost pins for non--communicating continues to operate the outdoor fan. The control Status LED will
systems as follows: flash the appropriate code shown in Table 21. After 15 minutes,
The brownout toggle is accomplished by shorting the defrost pins with a call for low or high stage cooling or heating, the compressor
from power up with the OAT and OCT sensor connector removed. contactor is energized. If the thermal protector has not re--set, the
After 3 seconds, the status of the force defrost short and the outdoor fan is turned off. If the call for cooling or heating
OAT/OCT as open will be checked. If correct, then the brownout continues, the control will energize the compressor contactor every
will be toggled. 15 minutes. If the thermal protector closes, (at the next 15 minute
S Status code 6 shows the brownout is disabled.
S Status code 5 shows the brownout is active. operation is locked out for 4 hours and the appropriate fault code is
After the brownout defeat is set, power down and reinstall the displayed.
OAT/OCT sensor and remove the short from the forced defrost Low or High Contactor Open (25HNB6 models) /
and OCT faults will not be cleared. The code will continue to be No 230V at Compressor Contractor (25HNB9
flashed. models)
The control is shipped with the brownout active. The change in If the compressor voltage is not sensed when the compressor
status is remembered until toggled to a new status. A power should be starting, the appropriate contactor may be stuck open or
down/power up sequence will not reset the status. It may be there is a wiring error. The control will flash the appropriate fault
necessary to do the toggle twice to cycle to the desired state of the code. Check the contactor and control box wiring.
defeat. Troubleshooting 25HNB9/25HNB6 units for
230V Line (Power Disconnect) Detection proper switching between low & high stages
If there is no 230v at the compressor contactor(s) when the indoor Check the suction pressures at the service valves. Suction pressure
unit is powered and cooling or heating demand exists, the should be reduced by 3--10% when switching from low to high
appropriate fault code is displayed. Verify the disconnect is closed capacity.
and 230v wiring is connected to the unit.
NOTE: The liquid pressures are very similar between low and
Compressor Voltage Sensing high stage operation, so liquid pressure should not be used for
The control board input terminals labeled VS, VR and L2 on troubleshooting.
25HNB6/24ANB7 models and VS and L2 on 25HNB9/24ANB1 Compressor current should increase 20--45% when switching from
models (see Fig. 44) are used to detect compressor voltage status low to high stage. The compressor solenoid when energized in
and alert the user of potential problems. The control continuously high stage, should measure 24vac.
monitors the high voltage on the run capacitor of the compressor When the compressor is operating in low stage the 24v DC
motor. Voltage should be present any time the compressor compressor solenoid coil is de--energized. When the compressor is
contactor is energized and voltage should not be present when the operating in high stage, the 24v DC solenoid coil is energized. The
contactor is de--energized. solenoid plug harness that is connected to the compressor HAS an
Contactor Shorted Detection internal rectifier that converts the 24v DC signal to 24v AC. DO
If there is compressor voltage sensed when there is no demand for NOT INSTALL A PLUG WITHOUT AN INTERNAL
compressor operation, the contactor may be stuck closed or there RECTIFIER.
may be a wiring error. The control will flash the appropriate fault Unloader Test Procedure
code. The unloader is the compressor internal mechanism, controlled by
25HNB6 Models -- Compressor Thermal Cutout the DC solenoid, that modulates between high and low stage. If it
The control senses the compressor voltage at VR and VS. When is suspected that the unloader is not working, the following
starting or running, a phase difference of the voltages on the inputs methods may be used to verify operation.
will indicate the thermal protector is closed. If the phase difference 1. Operate the system and measure compressor amperage.
is 5_ or less for 10 seconds, the internal protector is open. The Cycle the unloader on and off at 30 second plus intervals at
control de--energizes the appropriate compressor contactor for 15 the UI (from low to high stage and back to low stage). Wait
minutes, but continues to operate the outdoor fan. The control 5 seconds after staging to high before taking a reading. The
Status LED will flash the appropriate code shown in Table 21. compressor amperage should go up or down at least 20
After 15 minutes, with a call for low or high stage cooling or percent.
heating, the appropriate compressor contactor is energized. If the 2. If the expected result is not achieved, remove the solenoid
thermal protector has not re--set, the outdoor fan is turned off. If plug from the compressor and with the unit running and the
the call for cooling or heating continues, the control will energize UI calling for high stage, test the voltage output at the plug
the compressor contactor every 15 minutes. If the thermal with a DC voltmeter. The reading should be 4 to 18 volts.
protector closes, (at the next 15 minute interval check) the unit will 3. If the correct DC voltage is at the control circuit molded
resume operation. plug, measure the compressor unloader coil resistance. The
If the thermal cutout trips for three consecutive cycles, then unit resistance should be 32 to 60 ohms depending on
operation is locked out for 4 hours and the appropriate fault code is compressor temperature. If the coil resistance is infinity,
displayed. much lower than 32 ohms, or is grounded, the compressor
must be replaced.
63
Temperature Thermistors The thermistor comparison is not performed during low ambient
cooling or defrost operation.
Thermistors are electronic devices which sense temperature. As the
temperature increases, the resistance decreases. Thermistors are Failed Thermistor Default Operation
used to sense outdoor air (OAT) and coil temperature (OCT). Factory defaults have been provided in the event of failure of
Refer to Fig. 42 for resistance values versus temperature. outdoor air thermistor (OAT) and/or outdoor coil thermistor
If the outdoor air or coil thermistor should fail, the control will (OCT).
flash the appropriate fault code. (See Table 21.) If the OAT sensor should fail, low ambient cooling will not be
IMPORTANT: The outdoor air thermistor and coil thermistor allowed and the one--minute outdoor fan off delay will not occur.
should be factory mounted in the final locations. Check to Defrost will be initiated based on coil temperature and time.
ensure thermistors are mounted properly per Fig. 45 and Fig. If the OCT sensor should fail, low ambient cooling will not be
46. allowed. Defrost will occur at each time interval during heating
Thermistor Sensor Comparison operation, but will terminate after 5 minutes.
If there is a thermistor out of range error, defrost will occur at each
The control continuously monitors and compares the outdoor air
time interval during heating operation, but will terminate after 5
temperature sensor and outdoor coil temperature sensor to ensure
minutes.
proper operating conditions. The comparison is:
Count the number of short and long flashes to determine the
S In cooling if the outdoor air sensor indicates ≥ 10_F appropriate flash code. Table 21 gives possible causes and actions
warmer than the coil sensor (or) the outdoor air sensor related to each error.
are out of range.
S In heating if the outdoor air sensor indicates ≥ 35_F
warmer than the coil sensor (or) the outdoor air sensor
are out of range.
If the sensors are out of range, the control will flash the appropriate
fault code as shown in Table 21.
OAT Thermistor must be locked in

place with spherical nib end facing to-
wards the front of the control box OCT Thermistor
must be secured
tight on stub tube.
Fig. 45 – Outdoor Air Thermistor (OAT) Attachment

Fig. 46 – Outdoor Coil Thermistor (OCT) Attachment
64
Table 20—Two--Stage Compressor Resistances
(Winding Resistance at 70_F±20_)
Winding 25HNB624 25HNB636 25HNB648 25HNB660

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—TROUBLESHOOTING
AMBER
LED
OPERATION FAULT POSSIBLE CAUSE AND ACTION
FLASH
CODE
On solid,
Standby – no call for unit operation None Normal operation
no flash
System Commu- Communication with User Interface lost. Check wiring to UI, indoor and
16
nications Failure outdoor units
High Pressure High ---pressure switch trip. Check refrigerant charge, outdoor fan operation
31*
Switch Open and coils for airflow restrictions.
Low Pressure
32* Low---pressure switch trip. Check refrigerant charge and indoor air flow.
Switch Open
Brown Out (230v) 46
No 230v at Unit
There is no 230v at the contactor when indoor unit is powered and cooling/
Measured at L1
47 heating demand exists. Verify the disconnect is closed and 230v wiring is
and L2 on circuit
connected to the unit.
board
53
Outdoor Coil
Sensor Fault
56
Low Stage
Thermal Cutout
High Stage
Thermal Cutout
Contactor Shorted 73*
No 230V at
Compressor voltage not sensed when compressor should be starting. Con-
Compressor 74
tactor may be stuck open or there is a wiring error.
(25HNB9 Only)
81
82
Low---Pressure Low pressure switch trip has occurred during 3 consecutive cycles. Unit
83
84
* Sequence: Compressor contactor is de ---energized and outdoor fan is energized for up to 15 minutes. If demand still exists, control will energize
compressor contactor after 15 minute delay. If fault is cleared, unit will resume operation. If fault still exists, fan shuts off, and error code continues to flash.
Control will attempt re ---start every 15 minutes. Cycling low voltage defeats the 15 minute delay.
65
FAN 2 STAGE
COIL HEAT PUMP Variable Speed 2-Stage
THERMIDISTAT Thermidistat Furnace Heat Pump
O O
O
Y1 Y1
RVS/Heat Stage 2 O/B W2 RVS Cooling O/B W2 W2
Heat Stage 1 W/W1 W1 W1 Heat Stage 3 (furnace) W/W1 W/W1 W1 *
REMOVE J2
JUMPER FOR
Compressor Low Y1 W2 HEAT STAGING Heat/Cool Stage 1 Y1 / W2 Y1
Compressor High Y/Y2 Y/Y2 Y2 Heat/Cool Stage 2 Y/Y2 Y/Y2 Y2

Fan G G
Fan G G
24VAC Hot Cooling Rc
REMOVE J1 FOR
24VAC Hot Cooling Rc DEHUMIDIFY
DH Dry Contact 1 D1
MODES
Dry Contact 1 D1
Dry Contact 2 D2 DHUM
C C
Dry Contact 2 D2 24VAC Common C COM C
24VAC Common C Humidify HUM
Humidifier Solenoid
Humidify HUM Outdoor Air Temp OAT Valve *
Humidifier Solenoid
Outdoor Air Temp OAT Valve * Remote Room Sensor RRS Outdoor Sensor *
Remote Room Sensor RRS OAT/RRS Com SRTN Remote Room

Outdoor Sensor *
Sensor *
OAT/RRS Com OAT/RRS Remote Room
Sensor *
* Indicates connection may not be required / available.
A08055 A10107
Fig. 47 – Thermidistat Models T6-- PRH-- 01 or T6-- NRH-- 01) Fig. 48 – Thermidistat Model T6-- PRH-- 01 or T6-- NRH-- 01 with
Wiring with 2-- Stage Heat Pump (non-- communicating) Variable Speed Furnace and 2-- Stage Heat Pump
(non-- communicating)
User Interface Furnace or Fan Coil Communicating HP
D D D
C C C
B B B
A A A
R
OAT
R
Y
*
O
Humidifier
W
C
24vac C
HUM
A08091 * See Humidifier Instructions for proper wiring.
Fig. 49 – Variable Speed Furnace or Fan Coil Wiring with Commu- A09567
nicating 2-- Stage HP Fig. 50 – Single Stage Furnace with 2--Stage Air Conditioner
LEGEND
24v Factory Wiring
24v Field Wiring

R
Field Splice Connection
A09306
*
* See Humidifier Instructions for proper wiring.
A09568
Fig. 51 – 2--Stage Thermostat with Single--Stage Furnace and
2--Stage Air Conditioner
66
TWO STAGE NON--COMMUNICATING
24ACB7/25HCB6
These units are a low cost 2--stage option that is Airflow Selection for Variable Speed Furnaces
non--communicating utilizing 2 stage scroll technology. These (non--communicating)
units require Performance Boost furnace (58PH, 58MEB), variable
speed furnace (58MV, 58CV) or new model variable speed fan coil The variable speed furnaces provide blower operation to match the
(FV4C). Variable speed fan coils prior to the FV4C will NOT be capacities of the compressor during high and low stage cooling
rated with the new Comfort series two stage units as they are not operation. The furnace control board allows the installing
capable of meeting the air flow requirements necessary for rating. technician to select the proper airflows for each stage of cooling.
These are designed to operate with basic 24 volt thermostat inputs. Below is a summary of required adjustments. See furnace
installation instructions for more details:
Operating Ambient
1. Turn SW1--5 ON for 400 CFM/ton airflow or OFF for 350
The minimum outdoor operating ambient in cooling mode is 55_F CFM/ton airflow. Factory default is OFF.
(12.78_C), and the maximum outdoor operating ambient in
2. The A/C DIP switch setting determines airflow during high
cooling mode is 125_F (51.67_C) when operating voltage is 230v.
stage cooling operation. Select the A/C DIP switch setting
For 208v applications, the maximum outdoor ambient is 120_F.
corresponding to the available airflow shown in the furnace
NOTE: Units operating at high stage operation, 208v (or below) Installation Instructions that most closely matches the re-
line voltage and at an outdoor ambient of 120_F (or greater), may quired airflow shown in the air conditioning Product Data
experience compressor trip. for HIGH speed.
NOTE: This product is not approved for low ambient cooling at 3. The CF DIP switch setting determines airflow during low
this time, and no low ambient kit is available. stage cooling operation. Select the CF DIP switch setting
Airflow Selections (ECM Furnaces) corresponding to the available airflow shown in the furnace
installation instructions that most closely matches the re-
The ECM Furnaces provide blower operation to match the quired airflow shown in the air conditioning Product Data
capacities of the compressor during high and low stage cooling for LOW speed. If a higher or lower continuous fan speed is
operation. Tap selections on the furnace control board enable the desired, the continuous fan speed can be changed using the
installing technician to select the proper airflows for each stage of fan switch on the thermostat. Refer to the furnace Installa-
cooling. Below is a brief summary of the furnace airflow tion Instructions for details of how to use this feature.
configurations
1. The Y2 call for high stage cooling energizes the “Cool” tap
Airflow Selection for FV4C Fan Coils
on the control board. The grey wire from cool tap is connec- (non--communicating)
ted to tap 5 on the motor. Refer to the furnace Product Data The FV4 provides high-- and low--stage blower operation to match
to find the corresponding airflow. If the airflow setting for the capacities of the compressor at high-- and low--stage.
high cooling needs to be switched from tap 5 to a different To select recommended airflow, refer to the FV4C Installation
tap, jumper a connection from the cool tap to the desired tap Instructions. The FV4C utilizes an Easy Select control board that
so that the Y2 signal is communicated via the cool tap to the allows the installing technician to select proper airflows. This fan
desired speed tap. coil has an adjustable blower--off delay factory set at 90 sec. for
2. The Y1 call for low stage cooling energizes the “Fan” tap high-- and low--stage blower operation.
on the control board. The red wire from the fan tap is con-
nected to tap 1 on the motor. Refer to the furnace Product
Data to find the corresponding airflow. If the airflow setting
for low cooling needs to be switched from tap 1 to a differ-
ent tap, jumper a connection from the Fan tap to the desired
tap so that the Y1 signal is communicated via the Fan tap to
the desired speed tap. The Y1 setting will also govern the
continuous fan airflow for the furnace.
Refer to the literature for the furnace for further details.
67
SYSTEM FUNCTION AND SEQUENCE
OF OPERATION
NOTE: Defrost control board is equipped with 5 minute lockout Quiet Shift
timer that is initiated upon any interruption of power. Quiet shift is a field selectable defrost mode (factory set to OFF),
Turn on power to indoor and outdoor units. Transformer is which will eliminate occasional noise that could be heard at the
energized. start of defrost cycle and restarting of heating cycle. It is selected
Cooling by placing DIP switch 3 on defrost board (see Fig. 52) in the ON
position.
On a call for cooling, thermostat makes circuits R--O, R--Y, and
R--G. Circuit R--O energizes reversing valve, switching it to When Quiet Shift switch is placed in ON position, and a defrost is
cooling position. Circuit R--Y sends low voltage through the initiated, the following sequence of operation will occur. Reversing
safeties and energizes the T1 terminal on the circuit board. If the valve will energize, compressor will turn off for 30 seconds, and
compressor has been off for 5 minutes, or power has not been then turn back on to complete defrost. At the start of heating after
cycled for 5 minutes, the OF2 relay and T2 terminal will energize. conclusion of defrost, reversing valve will de--energize,
This will close the contactor, and start the outdoor fan motor and compressor will turn off for another 30 seconds, and the fan will
compressor. turn off for 40 seconds, before starting in the heating mode.
When the cycle is complete, R--Y is turned off, stopping the Defrost
compressor and outdoor fan. The 5 minute time guard begins The defrost control is a time/temperature control which has field
counting. Compressor will not come on again until this delay selectable settings of 30, 60, 90, or 120 minutes, factory set to 90
expires. In the event of a power interruption, the time guard will minutes. These settings represent the amount of time that must pass
not allow another cycle for 5 minutes. after closure of the defrost thermostat before the defrost sequence
NOTE: If the indoor blower off delay is enabled, it will run up to begins.
an additional 90 seconds to increase system efficiency. The defrost thermostat senses coil temperature throughout the
heating cycle. When the coil temperature reaches the defrost
Heating thermostat setting of approximately 32 _F (0 _C), it will close,
On a call for heating, thermostat makes circuits R--Y and R--G. which energizes the DFT terminal and begins the defrost timing
Circuit R--Y sends low voltage through the safeties and energizes sequence. When the DFT has been energized for the selected time,
the T1 terminal on the circuit board. T1 energizes the defrost logic the defrost cycle begins. Defrost cycle is terminated when defrost
circuit. If the compressor has been off for 5 minutes, or power thermostat opens, or automatically after 10 minutes.
has not been cycled for 5 minutes, the OF2 relay and T2 terminal Defrost Speedup
will energize. This will close the contactor, start the outdoor fan
To initiate a forced defrost, speedup pins (J1) must be shorted with
motor and compressor.
a flat head screwdriver for 5 seconds and RELEASED. If the
When the cycle is complete, R--Y is turned off , stopping the defrost thermostat is open, a short defrost cycle will be observed
compressor and outdoor fan. The 5 minute time guard begins (actual length depends on Quiet Shift switch position). When Quiet
counting. Compressor will not come on again until this time delay Shift is off, only a short 30 second defrost cycle is observed. With
expires. In the event of a power interruption, the time guard will Quiet Shift ON, the speedup sequence is one minute; 30 second
not allow another cycle for 5 minutes. compressor off period followed by 30 seconds of defrost with
Compressor Operation compressor operation. When returning to heating mode, the
The basic scroll design has been modified with the addition of an compressor will turn off for an additional 30 seconds and the fan
internal unloading mechanism that opens a by--pass port in the first for 40 seconds.
compression pocket, effectively reducing the displacement of the If the defrost thermostat is closed, a complete defrost cycle is
scroll. The opening and closing of the by--pass port is controlled initiated. If the Quiet Shift switch is turned on, the compressor will
by an internal electrically operated solenoid. The modulated scroll be turned off for two 30 second intervals as explained previously.
uses a single step of unloading to go from full capacity to
approximately 67% capacity.
T2 C C O
OF1
A single speed, high efficiency motor continues to run while the
OF2
scroll modulates between the two capacity steps. Modulation is

DFT
O R W2 Y C
achieved by venting a portion of the gas in the first suction pocket

T1
back to the low side of the compressor, thereby reducing the

effective displacement of the compressor.
Y
Full capacity is achieved by blocking these vents, thus increasing

P1
the displacement to 100%. A DC solenoid in the compressor

SPEEDUP
60
30
INTERVAL TIMER OFF
controlled by a rectified 24 volt AC signal in the external solenoid

J1
120
90
plug moves the slider ring that covers and uncovers these vents.
30
60
P3
DFT
The vent covers are arranged in such a manner that the compressor
ON
SHIFT
QUIET
operates at approximately 67% capacity when the solenoid is not HK32EA003
energized and 100% capacity when the solenoid is energized. The Speedup Quiet Defrost interval
loading and unloading of the two step scroll is done ”on the fly” Pins Shift DIP switches
without shutting off the motor between steps. A05378
NOTE: 67% compressor capacity translates to approximately 75% Fig. 52 – Defrost Control
cooling or heating capacity at the indoor coil.
The compressor will always start unloaded and stay unloaded for
five seconds even when the thermostat is calling for high stage
capacity.
68
CHECK CHARGE Verify 25HCB6 units for proper switching
Factory charge amount and desired subcooling are shown on unit between low & high stages
rating plate. Charging method is shown on information plate inside Check the suction pressures at the service valves. Suction pressure
unit. To properly check or adjust charge, conditions must be should be reduced by 3--10% when switching from low to high
favorable for subcooling charging. Favorable conditions exist capacity.
when the outdoor temperature is between 70_F and 100_F Compressor current should increase 20--45% when switching from
(21.11_C and 37.78_C), and the indoor temperature is between low to high stage. The compressor solenoid when energized in
70_F and 80_F (21.11_C and 26.67_C). Follow the procedure high stage, should measure 24vac.
below: When the compressor is operating in low stage the 24v DC
Unit is factory charged for 15ft (4.57 m) of lineset. Adjust charge compressor solenoid coil is de--energized. When the compressor is
by adding or removing 0.6 oz/ft (.018 kg/m) of 3/8 liquid line operating in high stage, the 24v DC solenoid coil is energized. The
above or below 15ft (4.57 m) respectively. solenoid plug harness that is connected to the compressor HAS an
For standard refrigerant line lengths (80 ft/24.38 m or less), allow internal rectifier that converts the 24v DC signal to 24v AC. DO
system to operate in cooling mode at least 15 minutes. If conditions NOT INSTALL A PLUG WITHOUT AN INTERNAL
are favorable, check system charge by subcooling method. If any RECTIFIER.
adjustment is necessary, adjust charge slowly and allow system to Unloader Test Procedure
operate for 15 minutes to stabilize before declaring a properly
charged system. The unloader is the compressor internal mechanism, controlled by
the DC solenoid, that modulates between high and low stage. If it
If the indoor temperature is above 80_F (26.67_C), and the is suspected that the unloader is not working, the following
outdoor temperature is in the favorable range, adjust system charge methods may be used to verify operation.
by weight based on line length and allow the indoor temperature to
drop to 80_F (26.67_C) before attempting to check system charge 1. Operate the system and measure compressor amperage.
by subcooling method as described above. Cycle the unloader on and off at 30 second plus intervals at
the thermostat (from low to high stage and back to low
If the indoor temperature is below 70_F (21.11_C), or the outdoor stage). Wait 5 seconds after staging to high before taking a
temperature is not in the favorable range, adjust charge for line set
reading. The compressor amperage should go up or down
length above or below 15ft (4.57 m) only. Charge level should then at least 20 percent.
be appropriate for the system to achieve rated capacity. The charge
level could then be checked at another time when the both indoor 2. If the expected result is not achieved, remove the solenoid
and outdoor temperatures are in a more favorable range. plug from the compressor and with the unit running and the
thermostat calling for high stage, test the voltage output at
NOTE: If line length is beyond 80 ft (24.38 m) or greater than 20
the plug with a DC voltmeter. The reading should be 24
ft (6.10 m) vertical separation, See Long Line Guideline for volts DC.
3. If the correct DC voltage is at the control circuit molded
Heating Check Chart Procedure plug, measure the compressor unloader coil resistance. The
To check system operation during heating cycle, refer to the resistance should be 32 to 60 ohms depending on com-
Heating Check Chart on outdoor unit. This chart indicates whether pressor temperature. If the coil resistance is infinite, much
a correct relationship exists between system operating pressure and lower than 32 ohms, or is grounded, the compressor must
air temperature entering indoor and outdoor units. If pressure and be replaced.
temperature do not match on chart, system refrigerant charge may
not be correct. Do not use chart to adjust refrigerant charge.
69
TWO STAGE COMMUNICATING 24APA7/25HPA6
These units provide a Infinity capable 2 stage product in the Data to find the corresponding airflow. If the airflow setting
Performance line utilizing 2 stage scroll technology. These units for low cooling needs to be switched from tap 1 to a differ-
are designed using the full--coil cabinet with is currently used for ent tap, jumper a connection from the Fan tap to the desired
the Comfort Series products. Although the deluxe cabinet used in tap so that the Y1 signal is communicated via the Fan tap to
other Performance Series products provides excellent sound levels, the desired speed tap. The Y1 setting will also govern the
serviceability and stylish appearance, its design does not allow for continuous fan airflow for the furnace.
coil surface area required to achieve targeted ratings. These units Refer to the furnace literature for further details.
require a variable speed furnace (58MV, 58CV) Performance Boost
furnace (58PH, 58MEB) or variable speed fan coil (FE4 or new Airflow Selection for Variable Speed Furnaces
FV4C) to achieve targeted ratings. (non--communicating)
These units are capable of operating with either Infinity User The variable speed furnaces provide blower operation to match the
Interface or basic 24 volt thermostat inputs. capacities of the compressor during high and low stage cooling
Indoor Thermostat Control Options operation. The furnace control board allows the installing
Infinity Standard 2--- stage technician to select the proper airflows for each stage of cooling.
Model Below is a summary of required adjustments. See furnace
Control Thermostat
25HPA6 Yes Yes installation instructions for more details:
1. Turn SW1----5 ON for 400 CFM/ton airflow or OFF for 350
Operating Ambient
CFM/ton airflow. Factory default is OFF.
The minimum outdoor operating ambient in cooling mode is 55_F
2. The A/C DIP switch setting determines airflow during high
(12.78_C) without low ambient cooling enabled, and the
stage cooling operation. Select the A/C DIP switch setting
maximum outdoor operating ambient in cooling mode is 125_F
(51.67_C). At line voltage of 208v (or below) and an outdoor
Installation Instructions that most closely matches the re-
ambient of 120_F (48.9_C) (and above), the compressor operates
quired airflow shown in the air conditioning Product Data
in low stage. On Infinity communicating systems ONLY, low
for HIGH speed.
ambient cooling operation is possible at ambient as low as 0_F
(--17.78_C). 3. The CF DIP switch setting determines airflow during low
stage cooling operation. Select the CF DIP switch setting
The maximum outdoor operating ambient in heating mode is
66°F/18.89_C on all models.
installation instructions that most closely matches the re-
Model Plug quired airflow shown in the air conditioning Product Data
Each control board contains a model plug. The correct model plug for LOW speed. If a higher or lower continuous fan speed is
must be installed for or the system to operate properly. (See Table desired, the continuous fan speed can be changed using the
22.) fan switch on the thermostat. Refer to the furnace Installa-
Table 22—Model Plug Information tion Instructions for details of how to use this feature.
PIN RESISTANCE Airflow Selection for FV4C Fan Coils Using
MODEL MODEL PLUG
NUMBER NUMBER
(K--- ohms) Non--Communicating (Non--Infinity) Thermostats
Pins 1--- 4 Pins 2--- 3 The FV4C provides high-- and low--stage blower operation to
25HPA624 HK70EZ041 18 91 match the capacities of compressor at high-- and low--stage. To
25HPA636 HK70EZ043 18 150 select recommended airflow, refer to FV4C Installation
25HPA648 HK70EZ045 18 220
Instructions. The FV4C utilizes an Easy Select control board that
25HPA660 HK70EZ047 18 360
allows the installing technician to select proper airflows. For
24APA724 Hk70EZ040 18 75
24APA736 Hk70EZ042 18 120
adjustments to control board, select appropriate HP SIZE and CFM
24APA748 Hk70EZ044 18 180 ADJUST setting. This fan coil has an adjustable blower off delay
24APA760 Hk70EZ046 18 270 factory set at 90 sec for high-- and low--stage blower operation.
The model plug is used to identify the type and size of unit to the When using a communicating (Infinity) control, dipswitch
control. adjustments are not necessary. Airflows are determined by Infinity
Control setup. The fan coil is the FE4A.
Airflow Selections for ECM Furnaces (non
For other combinations of equipment consult Product Data Digest.
communicating)
NOTE: Systems using only a non--communicating (non--Infinity)
The ECM Furnaces provide blower operation to match the thermostat, Carrier electronic thermostats are equipped with a
capacities of the compressor during high and low stage cooling 15--minute staging timer. This timer prevents the two--stage system
operation. Tap selections on the furnace control board enable the from operating at high stage until unit has been operating in low
installing technician to select the proper airflows for each stage of
stage for 15 minutes, unless there is at least a ±5°F (±2.8°C)
cooling. Below is a brief summary of the furnace airflow
difference between room temperature and thermostat set point. To
configurations
force high stage (after a minimum of 2 minutes in low stage),
1. The Y2 call for high stage cooling energizes the “Cool” tap
adjust the set point at least ±5°F (±2.8°C) below room ambient.
on the control board. The grey wire from cool tap is connec-
ted to tap 5 on the motor. Refer to the furnace Product Data
to find the corresponding airflow. If the airflow setting for
high cooling needs to be switched from tap 5 to a different
tap, jumper a connection from the cool tap to the desired tap
so that the Y2 signal is communicated via the cool tap to the
desired speed tap.
2. The Y1 call for low stage cooling energizes the “Fan” tap
on the control board. The red wire from the fan tap is con-
nected to tap 1 on the motor. Refer to the furnace Product
70
GENERAL INFORMATION
Infinity Controlled Low Ambient Cooling If the coil temperature does not reach 32_F (0_C) within the
interval, the interval timer will be reset and start over.
This unit is capable of low ambient cooling down to 0°F (--17.8°C)
without a kit ONLY when using an Infinity Control. A low S Upon initial power up the first defrost interval is defaulted to 30
ambient kit is not required for Infinity controlled low ambient minutes. Remaining intervals are at selected times.
operation. The Infinity Control provides an automatic evaporator S Defrost is only allowed to occur below 50_F (10_C) outdoor
freeze thermostat. Low ambient cooling must be enabled in the ambient temperature.
User Interface setup. Fan may not begin to cycle until about 40°F The outdoor fan output (ODF) will remain off for 20 seconds after
(4.4°C) OAT. Fan will cycle based on coil and outdoor air termination. This delay will allow time for the system to capture
temperature. the heat from the outdoor coil and reduce the “steam cloud” effect
that may occur on transition from defrost to heating cycle. The
Infinity controlled low ambient mode operates as follows:
S Fan is OFF when outdoor coil temperature is less than outdoor enable the fan to energize immediately at the time of termination
air temperature (+ 3 _F/1.7_C) or outdoor fan has been ON for
and 12 seconds prior to the reversing valve de--energizing through
30 minutes. (Fan is turned off to allow refrigerant system to
the User Interface setup screen (available with
stabilize.)
SYSTXCCUID01--C), or forced defrost pins as follows:
S Fan is ON when outdoor coil temperature is less than outdoor air
temperature (+25_F/13.9_C) or outdoor coil temperature is more The ODF fan delay defeat can be toggled by shorting the forced
than 80 _F (26.7 _C) or if outdoor fan has been OFF for 30 defrost pins for >15 seconds while in the standby mode (status
minutes. (Fan is turned on to allow refrigerant system to LED on solid). The LED will start to flash when the toggle has
stabilize.) taken place.
S Low pressure switch is ignored for first 3 minutes during low Status code 4 shows the fan delay defeat is active (no delay).
ambient start up. After 3 minutes, if LPS trips, then outdoor fan Status code 3 shows that it is not active (20 second delay).
motor is turned off for 10 minutes, with the compressor The code will continue to be displayed until after the short is
running. If LPS closes within 10 minutes then cooling removed. There is a 5 second wait before the code is cancelled
continues with the outdoor fan cycling per the coil temperature once the short is removed. the code that is flashing will finish
routine listed above for the remainder of the cooling cycle. If before going back to solid LED. The control is shipped with the
the LPS does not close within 10 minutes, then the normal LPS ODF fan delay defeat NOT active.
trip response (shut down cooling operation and generate LPS
The change in status is remembered until toggled to a new status.
trip error) will occur.
A power down/power up sequence will not reset the status. It may
Defrost be necessary to do the toggle twice to cycle to the desired state of
This control offers 5 possible defrost interval times: 30, 60, 90, 120 the defeat.
minutes, or AUTO. Defrost Hold
Defrost intervals are selected by dip switches on the unit control On a non--communicating system, if the thermostat becomes
board or by the Infinity Control User Interface. The Infinity satisfied (Y1 or Y1 and Y2) before the defrost cycle is terminated,
Control selection overrides the control board dip switch settings. the control will “hold” in defrost mode and finish the defrost cycle
Defrost interval times: 30, 60, 90, and 120 minutes or AUTO are on the next call for heat.
selected by the Infinity Control User Interface (the dip switches are On models with communicating Infinity Control, defrost hold is
not used.) not needed because the User Interface will complete the defrost
AUTO defrost adjusts the defrost interval time based on the last cycle before shutting down the system.
defrost time as follows: Forced Defrost
S When defrost time <3 minutes, the next defrost interval=120 On a system with non--communicating (non--Infinity) control,
minutes.
forced defrost can be initiated by manually shorting the 2--pin
S When defrost time 3--5 minutes, the next defrost interval=90 header labeled FORCED DEFROST (see Fig 6) on the control
minutes.
board for 5 seconds then releasing.
S When defrost time 5--7 minutes, the next defrost interval=60
minutes. On a system with communicating (Infinity) control, forced defrost
S When defrost time >7 minutes, the next defrost interval=30 is initiated with the User Interface.
minutes. On all models, during a Forced Defrost:
The control board accumulates compressor run time. As the S If coil temperature is at defrost temperature of 32_F (0_C), and
accumulated run time approaches the selected defrost interval time, outdoor air temperature is below 50_F (10_C), a full defrost
the control board monitors the coil temperature sensor for a defrost sequence will occur.
demand. If a defrost demand exists, a defrost cycle will be initiated S If coil temperature or outdoor air temperature does not meet the
at the end of the selected time interval. A defrost demand exists above requirements, an abbreviated 30 second defrost will
when the coil temperature is at or below 32_F (0_C) for 4 minutes occur.
during the interval.
65_F (18.33_C)or 10 minutes has passed. When OAT is > 25°F
(--3.9°C), defrost will occur in low or high stage as demanded by
the thermostat or User Interface.
If OAT is ≤25°F (3.9_C), defrost will occur in high stage only,
regardless of thermostat or User Interface demand, and will
terminate at 50_F (10_C) coil temperature with a minimum of 2.5
minutes in defrost.
71
Quiet Shift NOTE: If line length is beyond 80 ft (24.38 m) or greater than 20
Quiet Shift is a field--selectable defrost mode which may eliminate ft (6.10 m) vertical separation, See Long Line Guideline for
occasional noise that could be heard at the start of the defrost cycle special charging requirements.
and restarting of the heating cycle. On a non--communicating Heating Check Chart Procedure
system, this feature must be enabled by selecting the 3rd position To check system operation during heating cycle, refer to the Heat
of the 3--position dip switch. For communicating (Infinity) Pump Charging Instructions label on outdoor unit. This chart
systems, it must be enabled at the User Interface. When activated, indicates whether a correct relationship exists between system
the following sequence of operation will occur. Reversing valve operating pressure and air temperature entering indoor and outdoor
will energize and compressor will turn off for 30 seconds, then turn units. If pressure and temperature do not match on chart, system
back on to complete defrost. At the end of the defrost cycle, the refrigerant charge may not be correct. Do not use chart to adjust
reversing valve de--energizes, compressor will turn off for another refrigerant charge.
30 seconds, and the fan will turn off for 40 seconds, before starting
NOTE: In heating mode, check refrigerant charge only when
in the heating mode.
Liquid--Line Solenoid Accessory correct refrigerant charge.
In heat pump long--line applications, a liquid--line solenoid is NOTE: When charging is necessary during heating season, charge
required to control refrigerant migration in the heating mode. The must be weighed in accordance with unit rating plate, ±0.6 oz./ft
solenoid should be installed near the outdoor unit with the arrow (±17.74 g/m). of 3/8--in. liquid--line above or below 15 ft (4.57
facing the outdoor unit. This is the direction of flow control. See
m)., respectively.
application manual for long--line application details.
EXAMPLE:
Control: 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.
provided at the Y1 connection. Connect the solenoid as shown in MAJOR COMPONENTS
2--Stage Control Board
off mode, to prevent refrigerant migration into the unit through the The HP control board controls the following functions:
liquid--line. S High and low stage compressor contactor operation
On Systems with Accessory Liquid Solenoid Using a S Outdoor fan motor operation
Non--Communicating Thermostat: S Reversing valve operation
S Defrost operation
The liquid solenoid is connect to the Y1 and C terminal S Low ambient cooling
connections. The liquid solenoid closes, in the compressor off S Crankcase heater operation
mode, to prevent refrigerant migration into the unit through the S Compressor external protection
liquid--line. S Pressure switch monitoring
CHECK CHARGE S Time Delays
Charged in high or low stage Field Connections
Factory charge amount and desired subcooling are shown on unit On non--communicating (non--Infinity) system, the two--stage
rating plate for high stage. Charging method is shown on control receives 24vac low--voltage control system inputs through
information plate inside unit. To properly check or adjust charge, the R, C, Y1, Y2 and O connections located at the bottom of the
conditions must be favorable for subcooling charging. Favorable control board (see Fig. 53.) On a non--communicating system,
conditions exist when the outdoor temperature is between 70_F output W1 is connected at the bottom of the control board for
and 100_F (21.11_C and 37.78_C), and the indoor temperature is auxiliary heat.
between 70_F and 80_F (21.11_C and 26.67_C). Follow the For a communicating system, use the ABCD Infinity connections.
procedure below: Two Stage Compressor
Unit is factory charged for 15ft (4.57 m) of lineset. Adjust charge
The two stage compressor contains motor windings that provide
by adding or removing 0.6 oz/ft (17.74 g/m) of 3/8 liquid line
2--pole (3500 RPM) operation.
above or below 15ft (4.57 m) respectively.
For standard refrigerant line lengths (80 ft/24.38 m or less), allow Compressor Internal Relief
system to operate in cooling mode at least 15 minutes. If conditions The compressor is protected by an internal pressure relief (IPR)
are favorable, check system charge by subcooling method. If any which relieves discharge gas into the compressor shell when
adjustment is necessary, adjust charge slowly and allow system to differential between suction and discharge pressure exceeds
operate for 15 minutes to stabilize before declaring a properly 550--625 psi. The compressor is also protected by an internal
charged system. overload attached to motor windings.
If the indoor temperature is above 80_F (26.67_C), and the Compressor Control Contactor
outdoor temperature is in the favorable range, adjust system charge The contactor has a 24volt coil. The electronic control board
by weight based on line length and allow the indoor temperature to controls the operation of the contactor.
drop to 80_F (26.67_C) before attempting to check system charge
temperature is not in the favorable range, adjust charge for line set
length above or below 15ft (4.57 m) only. Charge level should then
be appropriate for the system to achieve rated capacity. The charge
level could then be checked at another time when the both indoor
and outdoor temperatures are in a more favorable range.
72
SYSTEM FUNCTIONS AND
SEQUENCE OF OPERATION
The 25HPA6 models utilize either an Infinity Communicating User voltage circuit to the motor. It does not change speeds between low
Interface or a 2-stage cooling indoor thermostat. With a call for and high stage operation.
first stage cooling, the outdoor fan and low-stage compressor are Time Delays
energized. If low-stage cannot satisfy cooling demand, high-stage
is energized by the second stage of indoor thermostat. After second The unit time delays include:
stage is satisfied, the unit returns to low-stage operation until first S Five minute time delay to start cooling or heating operation
stage is satisfied or until second stage is required again. when there is a call from the thermostat or user interface. To
bypass this feature, momentarily short and release Forced
When both first stage and second stage cooling are satisfied, the
Defrost pins.
compressor will shut off. When a 2-stage unit is operating at
low-stage, system vapor (suction) pressure will be higher than a
S Five minute compressor re--cycle delay on return from a
standard single-stage system or high-stage operation. brown--out condition.
S Two minute time delay to return to standby operation from last
When the outdoor ambient is more the 100_F (37.8_C), the valid communication (with Infinity only).
outdoor fan will continue to run for one minute after compressor S One minute time delay of outdoor fan at termination of cooling
shuts off. This reduces pressure differential for easier starting in mode when outdoor ambient is greater than or equal to 100_F
the next cycle. (37.78_C).
With non--communicating (non--Infinity) systems, with first stage S Fifteen second delay at termination of defrost before the
of cooling, Y1 and O are powered on; and with second stage of auxiliary heat (W1) is de--energized.
cooling, Y1, Y2, and O are on. For these systems, with first stage S Twenty second delay at termination of defrost before the
of heating Y1 is on and for second stage of heating, Y1 and Y2 are outdoor fan is energized (unless fan delay defeated).
on. When the reversing valve is energized, O is powered on. S Thirty second compressor delay when quiet shift enabled.
Communication and Status Function Lights S There is no delay between staging from low to high and from
high to low capacity. The compressor will change from low to
For Infinity Control only, Green communications (COMM)
high and from high to low capacity “on the fly” to meet the
Light
demand.
A green LED (COMM light) on the outdoor board indicates
successful communication with the other system products. The
Compressor Operation
green LED will remain OFF until communication is established. The basic scroll design has been modified with the addition of an
Once a valid command is received, the green LED will turn ON internal unloading mechanism that opens a by--pass port in the first
continuously. If no communication is received within 2 minutes, compression pocket, effectively reducing the displacement of the
the LED will be turned OFF until the next valid communication. scroll. The opening and closing of the by--pass port is controlled
Amber Status Light by an internal electrically operated solenoid. The modulated scroll
uses a single step of unloading to go from full capacity to
An amber colored STATUS light is used to display the operation approximately 67% capacity.
mode and fault codes as specified in the troubleshooting section.
A single speed, high efficiency motor continues to run while the
See Table 21 for codes and definitions.
scroll modulates between the two capacity steps. Modulation is
NOTE: Only one code will be displayed on the outdoor unit achieved by venting a portion of the gas in the first suction pocket
control board (the most recent, with the highest priority). back to the low side of the compressor, thereby reducing the
Crankcase Heater Operation effective displacement of the compressor.
The crankcase heater is energized during off cycle below 65°F Full capacity is achieved by blocking these vents, thus increasing
(18.33°C). the displacement to 100%. A DC solenoid in the compressor
controlled by a rectified 24 volt AC signal in the external solenoid
Outdoor Fan Motor Operation plug moves the slider ring that covers and uncovers these vents.
The outdoor unit control energizes outdoor fan anytime The vent covers are arranged in such a manner that the compressor
compressor is operating, except for defrost or low--ambient operates at approximately 67% capacity when the solenoid is not
cooling. The outdoor fan remains energized if a pressure switch or energized and 100% capacity when the solenoid is energized. The
compressor overload should open. Outdoor fan motor will loading and unloading of the two step scroll is done ”on the fly”
continue to operate for one minute after the compressor shuts off without shutting off the motor between steps.
when the outdoor ambient is greater than or equal to 100°F
NOTE: 67% compressor capacity translates to approximately 75%
(37.78°C). This reduces pressure differential for easier starting on
next cycle. cooling or heating capacity at the indoor coil.
The outdoor fan motor is a PSC type. A fan relay on the control The compressor will always start unloaded and stay unloaded for
board turns the fan off and on by opening and closing a high five seconds even when the thermostat is calling for high stage
capacity.
73
MODEL
PLUG
MODEL
PLUG
UTILITY RELAY *
UTILITY SIGNAL
OPEN RELAY LLS
A06525 A06526
TROUBLESHOOTING
Systems Communication Failure 7. In the event of a high--pressure switch trip or high--pressure
lockout, check the refrigerant charge, outdoor fan operation,
If communication with the Infinity control is lost with the User and outdoor coil (in cooling) for airflow restrictions, or in-
Interface, the control will flash the appropriate fault code. (See door airflow in heating.
Table 23.) Check the wiring to the User Interface and the indoor 8. In the event of a low--pressure switch trip or low--pressure
and outdoor units. lockout, check the refrigerant charge and indoor airflow
On new units, the model and serial numbers are input into the (cooling) and outdoor fan operation and outdoor coil in
board’s memory at the factory. If a model plug is lost or missing at heating.
initial installation, the unit will operate according to the Control Fault
information input at the factory and the appropriate error code will If the outdoor unit control board has failed, the control will flash
flash temporarily. An RCD replacement board contains no model the appropriate fault code (see Table 23). The control board should
and serial information. If the factory control board fails, the model be replaced.
plug must be transferred from the original board to the replacement
Brown--Out Protection
If the line voltage is less than 187v for at least 4 seconds, the
NOTE: The model plug takes priority over factory model
appropriate compressor contactor and fan relay are de--energized.
Compressor and fan operation are not allowed until voltage is a
minimum of 190v. The control will flash the appropriate fault code
model plug installed, and flash the appropriate fault code (see Table 23).
temporarily.
2230V Brown--Out Protection Defeated
Pressure Switch Protection
The brownout feature can be defeated if needed for severe noisy
The outdoor unit is equipped with high-- and low--pressure power conditions. This defeat should always be a last resort to
switches. If the control senses the opening of a high-- or solving the problem. Defeat is available on the User Interface
low--pressure switch, it will respond as follows: setup screen (available with SYSTXCCUID01--C), or can be
1. De--energize the compressor contactor. initiated through the forced defrost pins for non--communicating
2. Keep the outdoor fan operating for 15 minutes. systems as follows:
3. Display the appropriate fault code (see Table 23). The brownout toggle is accomplished by sorting the defrost pins
4. After a 15 minute delay, if there is a call for cooling or heat- from power up with the OAT and OCT sensor connector removed.
ing and LPS or HPS is reset, the compressor contactor is After 3 seconds, the status of the force defrost short and the
energized. OAT/OCT as open will be checked. If correct, then the brownout
5. If LPS or HPS has not closed after a 15 minute delay, the will be toggled.
outdoor fan is turned off. If the open switch closes anytime
after the 15 minute delay, then resume operation with a call Status code 6 shows the brownout is disabled.
for cooling or heating. Status code 5 shows the brownout is active.
6. If LPS or HPS trips 3 consecutive cycles, the unit operation After the brownout defeat is set, power down and reinstall the
is locked out for 4 hours. OAT/OCT sensor and remove the short from the forced defrost
74
and OCT faults will not be cleared. The code will continue to be Unloader Test Procedure
flashed.
The unloader is the compressor internal mechanism, controlled by
The control is shipped with the brownout active. The change in the DC solenoid, that modulates between high and low stage. If it
status is remembered until toggled to a new status. A power is suspected that the unloader is not working, the following
down/power up sequence will not reset the status. it may be methods may be used to verify operation.
necessary to do the toggle twice to cycle to the desired state of the
1. Operate the system and measure compressor amperage.
defeat.
Cycle the unloader on and off at 30 second plus intervals at
230V Line (Power Disconnect) Detection the User Interface (from low to high stage and back to low
If there is no 230v at the compressor contactor(s) when the indoor stage). Wait 5 seconds after staging to high before taking a
unit is powered and cooling or heating demand exists, the reading. The compressor amperage should go up or down
appropriate fault code is displayed. Verify the disconnect is closed at least 20 percent.
and 230v wiring is connected to the unit. 2. If the expected result is not achieved, remove the solenoid
Compressor Voltage Sensing plug from the compressor and with the unit running and the
User Interface or thermostat calling for high stage, test the
The control board input terminals labeled VS and L2 (see Fig. 53)
voltage output at the plug with a DC voltmeter. The read-
are used to detect compressor voltage status and alert the user of
ing should be 24 volts DC.
potential problems. The control continuously monitors the high
voltage on the run capacitor of the compressor motor. Voltage 3. If the correct DC voltage is at the control circuit molded
should be present any time the compressor contactor is energized plug, measure the compressor unloader coil resistance. The
and voltage should not be present when the contactor is resistance should be 32 to 60 ohms depending on com-
de--energized. pressor temperature. If the coil resistance is infinite, much
lower than 32 ohms, or is grounded, the compressor must
Contactor Shorted Detection be replaced.
If there is compressor voltage sensed when there is no demand for Temperature Thermistors
compressor operation, the contactor may be stuck closed or there
may be a wiring error. The control will flash the appropriate fault Thermistors are electronic devices which sense temperature. As the
code. temperature increases, the resistance decreases. Thermistors are
used to sense outdoor air (OAT) and coil temperature (OCT).
If the control senses the compressor voltage after start--up and is
Refer to Fig. 54 for resistance values versus temperature.
then absent for 10 consecutive seconds while cooling or heating
demand exists, the thermal protector is open. The control
de--energizes the compressor contactor for 15 minutes, but THERMISTOR CURVE
continues to operate the outdoor fan. The control Status LED will 90
flash the appropriate code shown in Table 23. After 15 minutes, 80
with a call for low or high stage cooling or heating, the compressor
RESISTANCE (KOHMS)
70
contactor is energized. If the thermal protector has not re--set, the 60
outdoor fan is turned off. If the call for cooling or heating 50
continues, the control will energize the compressor contactor every 40
15 minutes. If the thermal protector closes, (at the next 15 minute
30
20
10
operation is locked out for 4 hours and the appropriate fault code is
displayed. 0
0 20 40 60 80 100 120
No 230V at Compressor Contactor (-17.77) (-6.67) (4.44) (15.56) (26.67) (37.78) (48.89)
TEMPERATURE °F (°C)
If the compressor voltage is not sensed when the compressor
should be starting, the appropriate contactor may be stuck open or A08054
there is a wiring error. The control will flash the appropriate fault Fig. 54 – Resistance Values Versus Temperature
code. Check the contactor and control box wiring.
Troubleshooting units for proper switching If the outdoor air or coil thermistor should fail, the control will
flash the appropriate fault code. (See Table 23.)
between low & high stages
IMPORTANT: The outdoor air thermistor and coil thermistor
Check the suction pressures at the service valves. Suction pressure should be factory mounted in the final locations. Check to ensure
should be reduced by 3--10% when switching from low to high thermistors are mounted properly per Fig. 55 and Fig. 56.
capacity.
Compressor current should increase 20--45% when switching from
Thermistor Sensor Comparison
low to high stage. The compressor solenoid when energized in The control continuously monitors and compares the outdoor air
high stage, should measure 24vac. temperature sensor and outdoor coil temperature sensor to ensure
When the compressor is operating in low stage the 24v DC proper operating conditions. The comparison is:
compressor solenoid coil is de--energized. When the compressor is S In cooling if the outdoor air sensor indicates ≥ 10_F
operating in high stage, the 24v DC solenoid coil is energized. The (≥ 5.6_C) warmer than the coil sensor (or) the outdoor air
solenoid plug harness that is connected to the compressor HAS an sensor indicates ≥ 20_F (≥ 11_C) cooler than the coil sensor,
internal rectifier that converts the 24v DC signal to 24v AC. DO the sensors are out of range.
NOT INSTALL A PLUG WITHOUT AN INTERNAL S In heating if the outdoor air sensor indicates ≥ 35_F (≥ 19.4_C)
RECTIFIER. warmer than the coil sensor (or) the outdoor air sensor indicates
≥ 10_F (≥ 5.6_C) cooler than the coil sensor, the sensors are
out of range.
If the sensors are out of range, the control will flash the appropriate
fault code as shown in Table 23.
75
The thermistor comparison is not performed during low ambient If the OCT sensor should fail, low ambient cooling will not be
cooling or defrost operation. allowed. Defrost will occur at each time interval during heating
Failed Thermistor Default Operation operation, but will terminate after 5 minutes.
If there is a thermistor out of range error, defrost will occur at each
Factory defaults have been provided in the event of failure of
time interval during heating operation, but will terminate after 5
outdoor air thermistor (OAT) and/or outdoor coil thermistor
minutes.
(OCT).
Count the number of short and long flashes to determine the
If the OAT sensor should fail, low ambient cooling will not be
appropriate flash code. Table 23 gives possible causes and actions
allowed and the one--minute outdoor fan off delay will not occur.
related to each error.
Defrost will be initiated based on coil temperature and time.
OAT Thermistor must be

locked in place with spherical
nib end facing towards the OCT Thermistor
front of the control box must be secured
tight on stub tube.
Fig. 55 – Outdoor Air Thermistor (OAT) Attachment Fig. 56 – Outdoor Coil Thermistor (OCT) Attachment
76
Status Codes
Table 23—24APA7 / 25HPA6 TROUBLESHOOTING

AMBER LED
OPERATION FAULT FLASH POSSIBLE CAUSE AND ACTION
CODE
On solid, no
Standby – no call for unit operation None Normal operation
flash
System Commu- 16 Communication with User Interface lost. Check wiring to User Interface,
nications Failure indoor and outdoor units
High Pressure High ---pressure switch trip. Check refrigerant charge, outdoor fan operation
31*
Switch Open and coils for airflow restrictions.
Low Pressure
Switch or Dis- Low---pressure switch or discharge temperature switch trip. Check refrigerant
32*
charge Temp charge and indoor air flow.
Switch Open
Brown Out (230 v) 46
There is no 230v at the contactor when indoor unit is powered and cooling/
No 230v at Unit 47 heating demand exists. Verify the disconnect is closed and 230v wiring is
connected to the unit.
53
Outdoor Coil
Sensor Fault
56
Low Stage
Thermal Cutout
High Stage
Thermal Cutout
Contactor Shorted 73
No 230V at Compressor voltage not sensed when compressor should be starting. Con-
74
Compressor tactor may be stuck open or there is a wiring error.
81
82
Low---Pressure Low pressure switch trip has occurred during 3 consecutive cycles. Unit
83
84
* Sequence: Compressor contactor is de--- energized and outdoor fan is energized for up to 15 minutes. If demand still exists, control will energize compressor contactor after 15 minute
delay. If fault is cleared, unit will resume operation. If fault still exists, fan shuts off, and error code continues to flash. Control will attempt re--- start every 15 minutes. Cycling low voltage
defeats the 15 minute delay.
77
CARE AND MAINTENANCE Cleaning Coil
To assure high performance and minimize possible equipment 1. Remove top cover. (See Remove Top Cover in Cabinet
malfunction, it is essential that maintenance be performed section of this manual.)
periodically on this equipment. The frequency with which 2. Remove coil grilles or louvers (as applicable) to gain full
maintenance is performed is dependent on such factors as hours of access to coils for cleaning.
operation, geographic location, and local environmental NOTE: 4--sided deluxe units employ one louver spacer on each of
conditions. the four sides to prevent louver movement during operation. The
louver spacers are trapped between the coil surface and louver at
the approximate center of each side (See Fig. 4). This louver
! WARNING spacer should be present and, if dislodged during shipment, must
be reinstalled before unit is placed into operation.
or death.
! CAUTION
Disconnect all electrical power to unit before performing any UNIT DAMAGE HAZARD
maintenance or service on outdoor unit. Remember to Failure to follow this caution may result in equipment damage
disconnect power supply to air handler as this unit supplies or improper operation.
low--voltage power to the outdoor unit.
Coil fin damage can result in higher operating costs or
compressor damage. Do not use flame, high--pressure water,
The minimum maintenance that should be performed on this steam, volatile or corrosive cleaners on fins or tubing.
equipment is as follows:
1. Check outdoor coil for cleanliness each heating and cooling 3. Clean coil using vacuum cleaner and its crevice tool. Move
season and clean as necessary. crevice tool vertically, close to area being cleaned, making
2. Check fan motor and blade for cleanliness each month sure tool touches only dirt on fins and not fins. to prevent
fin damage, do not scrub fins with tool or move tool
during cooling season and clean as necessary.
horizontally against fins.
3. Check electrical connections for tightness and controls for
4. If oil deposits are present, spray coil with ordinary
proper operation each cooling season and service as
household detergent. Wait 10 minutes, and proceed to next
necessary. step.
5. Using garden hose, spray coil vertically downward with
! CAUTION constant stream of water at moderate pressure. Keep nozzle
at a 15-- to 20_ angle, about 3 in. from coil face and 18 in.
UNIT DAMAGE HAZARD from tube. Spray so debris is washed out of coil and
basepan.
damage or improper operation. 6. Reinstall top cover and position blade.
7. Reconnect electrical power and check for proper operation.
Because of possible damage to the equipment or personal
injury, maintenance should be performed by qualified Cleaning Outdoor Fan Motor and Blade
personnel only. 1. Remove fan motor and blade. Be careful not to bend or dent
fan blade.
Desert and Seacoast Locations 2. Clean motor and blade with soft brush or cloth. Be careful
Special consideration must be given to installation and not to disturb balance weights on fan blade.
maintenance of condensing units installed in coastal or desert 3. Check fan blade setscrew for tightness.
locations. This is because salt and alkali content of sand adheres to 4. Reinstall fan motor and blade to top cover and check for
aluminum fins of coil and can cause premature coil failure due to alignment.
corrosion.
5. Reinstall top cover and position blade.
Preventive measures can be taken during installations, such as: 6. Reconnect electrical power and check for proper operation.
1. Locate unit on side of structure opposite prevailing winds.
Electrical Controls and Wiring
2. Elevate unit to height where drifting sand cannot pile up
1. Disconnect power to both outdoor and indoor units.
against coil. Mounting feet, 4 in. high, are available as
accessories and can be used to elevate unit. 2. Check all electrical connections for tightness. Tighten all
screws on electrical connections. If any connections appear
3. Addition of coastal filter (See Product Data Digest for to be burned or smoky, disassemble the connection, clean
accessory listing). all parts and stripped wires, and reassemble. Use a new
Maintenance in desert and seacoast locations: connector if old one is burned or corroded, and crimp
1. Frequent inspection of coil and basepan especially after tightly.
storms and/or high winds. 3. Reconnect electrical power to indoor and outdoor units and
2. Clean coil by flushing out sand from between coil fins and observe unit through 1 complete operating cycle.
out of basepan as frequently as inspection determines 4. If there are any discrepancies in operating cycle,
necessary. troubleshoot to find cause and correct.
3. In off season, cover with covering that allows air to circulate Refrigerant Circuit
through but prevents sand from sifting in (such as canvas 1. Check refrigerant charge using the superheat method, and if
material). Do not use plastic as plastic will hold moisture low on charge, check unit for leaks using an electronic leak
possibly causing corrosion. detector.
2. If any leaks are found, remove and reclaim or isolate charge
(pumpdown) if applicable. Make necessary repairs.
3. Evacuate, recharge, and observe unit through 1 complete
operating cycle.
78
Final Check--Out
After the unit has been operating, the following items should be 3. Check to be sure tools, loose parts, and debris are removed
checked. from unit.
1. Check that unit operational noise is not excessive due to 4. Check to be sure all panels and screws are in place and tight.
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.
PURONR (R--410A) REFRIGERANT QUICK REFERENCE GUIDE
S Puron refrigerant operates at 50--70 percent higher pressures than R--22. Be sure that servicing equipment and replacement
components are designed to operate with Puron refrigerant.
S Puron refrigerant cylinders are rose colored.
S Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
S Puron refrigerant systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose
when charging into suction line with compressor operating
S Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low--side retard.
S Use hoses with 700 psig service pressure rating.
S Leak detectors should be designed to detect HFC refrigerant.
S Puron refrigerant, as with other HFCs, is only compatible with POE oils.
S Vacuum pumps will not remove moisture from oil.
S Do not use liquid--line filter driers with rated working pressures less than 600 psig.
S Do not leave Puron refrigerant suction line filter driers in line longer than 72 hours.
S Do not install a suction--line filter drier in liquid line.
S POE oils absorb moisture rapidly. Do not expose oil to atmosphere.
S POE oils may cause damage to certain plastics and roofing materials.
S Wrap all filter driers and service valves with wet cloth when brazing.
S A factory approved liquid--line filter drier is required on every unit.
S Do NOT use an R--22 TXV.
S If indoor unit is equipped with an R--22 TXV or piston metering device, it must be changed to a hard shutoff Puron TXV.
S Never open system to atmosphere while it is under a vacuum.
S When system must be opened for service, recover refrigerant, evacuate then break vacuum with dry nitrogen and replace filter
driers. Evacuate to 500 microns prior to recharging.
S Do not vent Puron refrigerant into the atmosphere.
S Do not use capillary tube coils.
S Observe all warnings, cautions, and bold text.
S All indoor coils must be installed with a hard shutoff Puron TXV metering device.
79
AIR CONDITIONER
TROUBLESHOOTING CHART
NO COOLING OR
INSUFFICIENT
COOLING
COMPRESSOR COMPRESSOR
COMPRESSOR RUNS BUT RUNS BUT
WILL NOT RUN CYCLES ON INSUFFICIENT
INTERNAL COOLING
OVERLOAD
OUTDOOR FAN
CONTACTOR CONTACTOR STOPPED OR LOOSE LEAD LOW SUCTION HIGH SUCTION HIGH SUCTION
OPEN CLOSED CYCLING ON AT FAN MOTOR PRESSURE LOW HEAD LOW
OVERLOAD PRESSURE SUPERHEAT
COMPRESSOR OUTDOOR AIR DEFECTIVE

POWER SUPPLY POWER SUPPLY RESTRICTED OR MOTOR DIRTY AIR COMPRESSOR UNIT
OPEN RECIRCULATING DEFECTIVE FILTERS VALVES OVERCHARGED
DEFECTIVE RESTRICTED INCORRECT INTERNAL INCORRECT

LOW-VOLTAGE LOOSE LEADS AT DISCHARGE OFM DUCT PRESSURE
COMPRESSOR RESTRICTED SIZE
TRANSFORMER TUBE CAPACITOR RELIEF OPEN PISTON
OVERCHARGE FAILED
OPEN FAULTY START OR NON- DAMPERS TXV
THERMOSTAT GEAR (1-PH) CONDENSABLES PARTLY CLOSED
IN SYSTEM
OPEN SHORTED
OR GROUNDED LOW
OPEN CONTROL REFRIGERANT INDOOR COIL
CIRCUIT COMPRESSOR
CHARGE FROSTED
MOTOR
WINDINGS
LINE VOLTAGE SLIGHTLY

LOSS OF COMPRESSOR TOO HIGH OR LOW ON
CHARGE STUCK LOW REFRIGERANT
COMPRESSOR LIQUID LINE

CONTACTOR OR INTERNAL DEFECTIVE RUN SLIGHTLY
COIL DEFECTIVE PROTECTION CAPACITOR RESTRICTED
OPEN
LOOSE
ELECTRICAL DEFECTIVE RUN COMPRESSOR PISTON
CONNECTION CAPACITOR BEARINGS RESTRICTED
DEFECTIVE
START HIGH INCORRECT
SUPERHEAT SIZE
CAPACITOR PISTON
DEFECTIVE INDOOR COIL

START STRAINER
CAPACITOR RESTRICTED
INDOOR
BLOWER MOTOR
DEFECTIVE OR
CYCLING ON OL
A90208
Fig. 57 – Air Conditioner Troubleshooting Chart
80
HEAT PUMP
TROUBLESHOOTING HEATING CYCLE
NO HEATING OR
INSUFFICIENT
HEATING
COMPRESSOR RUNS BUT RUNS
INTERNAL HEATING
OVERLOAD
DIRTY FILTERS
CONTACT CONTACTOR OR INDOOR LOW SUCTION STRIP HEATERS
OPEN CLOSED COIL LOW HEAD NOT OPERATING
DEFECTIVE LOW- INDOOR FAN

STOPPED OR DEFECTIVE FAN OUTDOOR
VOLTAGE COMPRESSOR MOTOR OUTDOOR FAN OUTDOOR FAN THERMOSTAT
TRANSFORMER POWER SUPPLY CYCLING ON STOPPED RUNNING
OVERLOAD CAPACITOR DEFECTIVE
REMOTE
CONTROL DAMAGED LOOSE LEADS LOOSE LEADS
LOOSE LEADS AT REVERSING AT AT OUTDOOR REVERSING ODT SETTING
CENTER COMPRESSOR VALVE STUCK TOO LOW
DEFECTIVE VALVE FAN MOTOR FAN MOTOR
CAP TUBE
CONTACTOR FAN MOTOR INTERNAL FAN PINCHED OR
COIL OPEN OR FAULTY START RESTRICTION IN BURNED MOTOR KLIXON RESTRICTED
GEAR (1-PH) DISCHARGE LINE LIQUID LINE BULB NOT
SHORTED OUT OPEN SENSING TRUE
ODT
OVERCHARGE PISTON STRIP HEATER

OPEN INDOOR COMPRESSOR OR NON- FAN MOTOR RESTRICTED OR RELAY OR
THERMOSTAT STUCK CONDENSABLES BURNED OUT IS CLOGGED CONTACTOR
IN SYSTEM DEFECTIVE
COMPRESSOR DEFROST RELAY OPENING IN

LIQUID-LINE LOW POWER CIRCUIT
PRESSURE INTERNAL REFRIGERANT N.C. CONTACTS UNDER-
OVERLOAD OPEN ON CHARGED TO HEATER
SWITCH OPEN CHARGE ELEMENTS
OPEN CIRCUIT BOARD
OPEN SHORTED LINE VOLTAGE

LOSS OF OR GROUNDED TOO HIGH OR OUTDOOR COIL BROKEN FUSE
CHARGE COMPRESSOR LOW DIRTY LINK
WINDINGS
DEFECTIVE RUN BROKEN

OPEN CONTROL DEFECTIVE RUN CAPACITOR STRAINER HEATER
CIRCUIT CAPACITOR (1-PH) RESTRICTED ELEMENT
DEFECTIVE OUTDOOR COIL OPEN (KLIXON)

START COMPRESSOR HEAVILY OVER
CAPACITOR BEARINGS FROSTED TEMPERATURE
THERMOSTAT
FAN MOTOR DEFECTIVE

HIGH-LOAD CONTACTS DEFECTIVE ROOM
CONDITION WELDED CLOSED DEFROST THERMOSTAT
IN DEFROST THERMOSTAT (2ND STAGE)
RELAY
DEFROST
REVERSING REVERSING THERMOSTAT IN
VALVE JAMMED VALVE DID NOT POOR PHYSICAL
IN MIDPOSITION SHIFT CONTACT WITH
TUBE
UNIT NOT
HIGH PROPERLY DEFECTIVE
SUPERHEAT CHARGED CIRCUIT BOARD
BAD ELECTRICAL
DEFECTIVE CONNECTION
ANYWHERE IN
START DEFROST
CAPACITOR CIRCUIT
A90206
Fig. 58 – Heat Pump Troubleshooting -- Heating Cycle
81
HEAT PUMP
TROUBLESHOOTING COOLING CYCLE
NO COOLING OR
INSUFFICIENT
COOLING
COMPRESSOR RUNS BUT RUNS BUT
INTERNAL COOLING
OVERLOAD
OUTDOOR FAN
STOPPED OR HIGH SUCTION HIGH SUCTION
CONTACTOR CONTACTOR LOOSE LEAD LOW SUCTION
LOW HEAD LOW
OPEN CLOSED CYCLING ON AT FAN MOTOR PRESSURE
OVERLOAD PRESSURE SUPERHEAT
COMPRESSOR OUTDOOR AIR DEFROST RELAY REVERSING

POWER SUPPLY RESTRICTED OR N.C. CONTACTS DIRTY AIR VALVE HUNG UP UNIT
POWER SUPPLY OR INTERNAL
OPEN RECIRCULATING OPEN FILTERS OVERCHARGED
LEAK
DAMAGED OR
DEFECTIVE STUCK DEFECTIVE INCORRECT
LOW-VOLTAGE LOOSE LEADS AT MOTOR DUCT COMPRESSOR SIZE
COMPRESSOR REVERSING DEFECTIVE RESTRICTED
TRANSFORMER VALVE VALVES PISTON
RESTRICTED INCORRECT INTERNAL FAILED

OPEN FAULTY START DISCHARGE OFM DAMPERS PRESSURE TXV
THERMOSTAT GEAR (1-PH) TUBE CAPACITOR PARTLY CLOSED RELIEF OPEN
OPEN SHORTED OVERCHARGE

OR GROUNDED DEFECTIVE
OPEN CONTROL OR NON- DEFROST INDOOR COIL
COMPRESSOR CONDENSABLES
CIRCUIT MOTOR THERMOSTAT FROSTED
IN SYSTEM
WINDINGS
LOW SLIGHTLY
LOSS OF COMPRESSOR REFRIGERANT LOW ON
CHARGE STUCK CHARGE REFRIGERANT
COMPRESSOR LINE VOLTAGE LIQUID LINE

CONTACTOR OR INTERNAL TOO HIGH OR SLIGHTLY
COIL DEFECTIVE PROTECTION LOW RESTRICTED
OPEN
LOOSE
ELECTRICAL DEFECTIVE RUN DEFECTIVE RUN PISTON
CONNECTION CAPACITOR CAPACITOR RESTRICTED
DEFECTIVE INCORRECT
START COMPRESSOR
BEARINGS SIZE
CAPACITOR PISTON
INDOOR COIL
HIGH STRAINER
SUPERHEAT RESTRICTED
DEFECTIVE INDOOR
START BLOWER MOTOR
CAPACITOR DEFECTIVE OR
CYCLING ON OL
A90207
Fig. 59 – Heat Pump Troubleshooting -- Cooling Cycle
82
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fitting Losses in Equivalent Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Puron System Suction Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
R--22 System Suction Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Puron Refrigerant Pressure Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
R--22 Refrigerant Pressure Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Puron Subcooling Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Puron Superheat Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
R--22 Subcooling Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
R--22 Superheat Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TWO--STAGE 25HNA / 24ANA
Model Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Outdoor Fan Motor PWM Above 55_F/12.7_C Outdoor Temp (DC volts, Tolerance +/-- 2%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Two--Stage Compressor Resistances (Winding resistance at 70_F ± 20_) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TWO--STAGE 25HNB / 24ANB
Outdoor Fan Motor PWM Above 55_F/12.7_C Outdoor Temp (DC volts, Tolerance +/-- 2%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Two--Stage Compressor Resistances (Winding resistance at 70_F ± 20_) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TWO--STAGE NON--COMMUNICATING 24ACB7 / 25HCB6, COMMUNICATING 24APA7 / 25HPA6
83
Copyright 2011 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 11/11 Catalog No.24---25---3SM
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces:24--- 25--- 2SM
84

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Residential Air Conditioners and Heat Pumps

Using R---22 and Puronr Refrigerant

TWO STAGE NON--COMMUNICATING Airflow Selection for VS Furnaces (non--comm) . . . . . . . . . . . 70

AIR CONDITIONER AND HEAT PUMP MODEL NUMBER NOMENCLATURE

SERIAL NUMBER NOMENCLATURE

Week of Manufacture Serial Number

Table 1—Required Field--Installed Accessories for Air Conditioners

Table 2—Required Field--Installed Accessories for Heat Pumps

Entry, Mid Tier, and 4 Sided Deluxe Units (in.)

Fig. 2 – Deluxe (3--sided) Baffle Assembly and Dimensions

Performance / Infinity Base --- Puron

Base and Comfort HP Control Box

Fig. 5 – Base and Comfort Series Control Box Identification

Fig. 6 – Figure Labels

Circuit R--O energizes reversing valve switching it to cooling THERMOSTAT INPUTS

terminal on the circuit board. T1 energizes the defrost logic circuit.

expires. In the event of a power interruption, the time guard will

not allow another cycle for 5 minutes.

HK32EA003 The defrost control is a time/temperature control that has field

Scroll Gas Flow Mechanical Failures

OHMMETER 2 3 (SMALLEST RESISTANCE) 2 IS COMMON (C)

Servicing Systems on Roofs With Synthetic Brazing

tightened to attain a metal--to--metal seal. If accessory pressure

Refer to Fig. 23 and install filter drier as follows:

UNIT OPERATION HAZARD

damage or improper operation.

3000 adjustment is necessary, adjust charge slowly and allow system to

BREAK VACUUM WITH DRY NITROGEN

BREAK VACUUM WITH DRY NITROGEN

CHECK FOR TIGHT, DRY SYSTEM

S Indoor air filter S If superheat is higher than 15°F, proceed to Step 3

Example 1 NOTE: The additional superheat at the compressor is due

Example 2 Examining the lineset, Jason finds approximately 145 ft of suction

Fig. 33 – Pseudo Evaporator Superheat Pressure and Temperature Measurement Locations

R---22 Liquid Line Temperature (_F)

R---22 Vapor Line Temperature (_F)

Fig. 35 – Performance and Infinity Series Control Box Identification

* SUPPLIED BY UTILITY PROVIDER Liquid Line Solenoid

OAT Thermistor must be locked in

Fig. 37 – Outdoor Air Thermistor (OAT) Attachment

Table 16—Two--Stage Compressor Resistances

Winding 25HNA624 25HNA636 25HNA648 25HNA660

25HCB624 25HCB636 25HCB648 25HCB660

User Interface Furnace or Fan Coil Communicating HP

24ANB124 HK70EZ009 5.1 91

* SUPPLIED BY UTILITY PROVIDER Liquid Line Solenoid

OAT Thermistor must be locked in

Fig. 45 – Outdoor Air Thermistor (OAT) Attachment

Winding 25HNB624 25HNB636 25HNB648 25HNB660

Run (R-- C) 1.32 0.89 0.64 0.49

Compressor High Y/Y2 Y/Y2 Y2 Heat/Cool Stage 2 Y/Y2 Y/Y2 Y2

Remote Room Sensor RRS OAT/RRS Com SRTN Remote Room

User Interface Furnace or Fan Coil Communicating HP

A08091 * See Humidifier Instructions for proper wiring.

24v Factory Wiring

24v Field Wiring

scroll modulates between the two capacity steps. Modulation is

achieved by venting a portion of the gas in the first suction pocket

back to the low side of the compressor, thereby reducing the

Full capacity is achieved by blocking these vents, thus increasing