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 REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . 23 -- 31
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION GUIDELINE . . . . . . . . . . . . . . . . . . . . . . . . 3 Servicing Systems on Roofs With Synthetic Materials . . . . 24
ACCESSORY DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . 4 -- 5 Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LOW--AMBIENT GUIDELINE . . . . . . . . . . . . . . . . . . . . . . 6 -- 7 Service Valves and Pump down . . . . . . . . . . . . . . . . . 25 -- 27
LONG LINE GUIDELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Liquid Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CABINET ASSEMBLY & COMPONENTS . . . . . . . . . . . 8 -- 10 Suction Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -- 13 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Aluminum Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Thermostatic Expansion Valve (TXV) . . . . . . . . . . . . 30 -- 31
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REFRIGERATION SYSTEM REPAIR . . . . . . . . . . . . . . 32 -- 34
Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cycle Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Compressor Removal and Replacement . . . . . . . . . . . . . . . 33
Time--Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 System Clean--Up After Burnout . . . . . . . . . . . . . . . . . . . . 33
PRESSURE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . 13 -- 14 Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Low--Pressure Switch (AC only) . . . . . . . . . . . . . . . . . 13 CHECK CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
High--Pressure Switch (AC & HP) . . . . . . . . . . . . . . . . 14 TROUBLESHOOTING WITH SUPERHEAT . . . . . . . . . 34 -- 44
Loss Of Charge Switch (HP only) . . . . . . . . . . . . . . . . 14 TWO--STAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 -- 57
TECH ASSIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 -- 15 Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DEFROST THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Airflow Selections for 24ANA7/25HNA6 using
DEFROST CONTROL BOARD . . . . . . . . . . . . . . . . . . . 16 -- 19 Non--Communicating Thermostats . . . . . . . . . . . . . . . . . . . 46

HK32EA001—Defrost Control . . . . . . . . . . . . . . . . . . 18 Airflow Selections for FV Fan coils for 24ANA7/25HNA6

using Non--Communicating Thermostats . . . . . . . . . . . . . . 46
HK32EA003—Defrost Control . . . . . . . . . . . . . . 18 -- 19
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Check Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 -- 48
COMPRESSOR PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Function and Sequence of Operation . . . . . . . . . . . 49
LOW--VOLTAGE TERMINALS . . . . . . . . . . . . . . . . . . . . . . . 19
Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 -- 51
COPELAND SCROLL COMPRESSOR . . . . . . . . . . . . 20 -- 23
Fan Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Compressor Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ECM Fan Motor Troubleshooting . . . . . . . . . . . . . . . . 51
Mechanical Failures . . . . . . . . . . . . . . . . . . . . . . . . . . 20 -- 21
Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electrical Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 -- 23
Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Muffler, Accumulator, Reversing Valve (RVS) . . . . . . . . . . 51
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 -- 57
 TABLE OF CONTENTS (CONTINUED)

CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . 58 -- 59 AC TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . 62

PURON QUICK REFERENCE GUIDE . . . . . . . . . . . . . . . . . 59 HP TROUBLESHOOTING CHART -- HEATING CYCLE . . 63
PRESSURE VS. TEMPERATURE CHART . . . . . . . . . . . . . . 60 HP TROUBLESHOOTING CHART -- COOLING CYCLE . . 64
REQUIRED LIQUID LINE TEMPERATURE . . . . . . . . . . . . 61 INDEX OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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
Cooling
Series Family Tier Major SEER Variations Open Open Voltage Minor Packaging Parts Identi- Open
Capacity
Series Series fication
(Tons)
0 = Recip.
18 = 1-- 1/2
1 = 575-- 3 1 = Scroll
24 =2 A = Standard
B = Base 3 = 13 SEER 3 = 208/230-- 1 2 = Staged
30 = 2-- 1/2 C = Coastal 0= 0= 0=
24 = AC A = A/C C = Comfort A = Puron 5 = 15 SEER 5 = 208/230-- 3 0 = Domestic Recip. 0 = Not
36 =3 F = Full Featured Not Not Initial
25 = HP H = HP P = Performance R = R22 6 = 16 SEER 6 = 460-- 3 1 = Import 3 = Staged Defined
42 = 3-- 1/2 G = Dense Grill Defined Defined Series
N = Infinity 8 = 18 SEER 7 = 230-- 1-- 50 Scroll
48 =4 L = Louvers
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 5 miles of the
ocean. Salt water can be carried as far away as 5 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 LOW --- AMBIENT
REQUIRED FOR LONG LINE
Accessory COOLING APPLICATIONS
APPLICATIONS* (Over 80 ft. / 24.38 m)
(Below 55°F / 12.8°C)
Crankcase Heater Yes Yes
Compressor Start Assist Capacitor and Relay Yes Yes
Yes
Evaporator Freeze Thermostat No
(For non ---Infinity systems only)
Liquid Line Solenoid Valve No See Long --- Line Application Guideline
Yes
Low--- ambient Pressure Switch No
(For non ---Infinity system only)
Support Feet Recommended No
Thermal Expansion Valve (TXV)
Yes Yes
Hard Shutoff
Yes
Winter Start Control No
(For non ---Infinity systems only)
* 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 Split--- System Longline Application Guideline.

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

REQUIRED FOR LOW --- AMBIENT REQUIRED FOR REQUIRED FOR
ACCESSORY COOLING APPLICATIONS LONG LINE APPLICATIONS* SEA COAST APPLICATIONS
(Below 55°F / 12.8°C) (Over 80 ft. / 24.38 m) (Within 2 miles / 3.22 km)
Accumulator Standard Standard Standard
Compressor Start Assist
Yes Yes No
Capacitor and Relay

Crankcase Heater Yes Yes No

Yes
Evaporator Freeze Thermostat No No
(for non ---Infinity systems only)
Yes
Isolation Relay No No
(for non ---Infinity systems only)
See Long --- Line Application
Liquid Line Solenoid Valve No No
Guideline
Motor Master® Control or Yes
No No
Low Ambient Switch (for non ---Infinity systems only)
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 Split--- System Longline Application Guideline.

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 and Mid---Tier Units (in.)
UNIT
AA UNIT HEIGHT A B C ---1 C ---2 C ---3 D
SIZE
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 Baffle Assembly

6
 BAFFLE-1
MA
TL: 20 GA STEEL

A06230
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 Baffle Assembly and Dimensions

7
LONG LINE GUIDELINE CABINET ASSEMBLY
Refer to Long Line Guideline for Puronr Refrigerant Air Basic Cabinet Designs
Conditioners and Heat Pumps or Long Line Guideline for R--22
Certain maintenance routines and repairs require removal of the
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).

Performance / Infinity
Comfort

Base --- Puron Base --- Puron with Wrap Grille

(no longer in production)

Base --- R22 with Wrap Grille

Base --- R22
(no longer in production)
Fig. 3 – Cabinet Designs

8
Access Compressor Or Other Internal Cabinet Remove Fan Motor Assembly -- Mid--Tier / Deluxe
Components 1. Perform items 1 through 6 from above.
NOTE: It is not necessary to remove the top cover to gain access. 2. Remove nuts securing fan motor to top cover.
Removing the top cover may cause grill panels, corner posts, 3. Remove motor and fan blade assembly.
louvers or coils to be damaged. It is recommended to protect the 4. Reverse sequence for reassembly.
top cover from damage of tools, belt buckles, etc. while servicing
5. Prior to applying power, check that fan rotates freely.
from the top.
1. Should the unit height allow components to be accessed
Control Box Cover—Base Products
from the top of the unit, follow procedures for removing fan This panel contains much of the same information as the
motor assembly. Access components through the top cap. information plate mentioned previously, but is designed only to
2. Large components may not be removed easily without cover the control box.
having access from the top and side. Side access may allow Remove Top Cover—Base Products
procedures such as brazing, cutting, and removal easier. 1. Turn off all power to outdoor an indoor units.
Follow procedures below:
2. Remove 5 screws holding top cover to coil grille and coil
a. Follow procedures to remove the fan motor assembly. tube sheet.
b. Air conditioning units only, remove the screws from the top 3. Remove 2 screws holding control box cover.
of the electrical control panel. (Heat pumps will not have
4. Remove 2 screws holding information plate.
screws holding the electrical control panel in place at the top
once the control box cover has been removed.) 5. Disconnect fan motor wires, cut any wire ties, and move
wires out of control box and through tube clamp on back of
c. Remove the base pan screws holding the control panel and control box.
lift off the unit.
6. Lift top cover from unit.
Certain maintenance routines and repairs require removal of
cabinet panels. 7. Reverse sequence for reassembly.

Remove Top Cover -- Mid--Tier / Deluxe Remove Fan Motor Assembly—Base Products
1. Turn off all power to outdoor and indoor units. 1. Perform items 1, 3, 4, and 5 above. (Note: item 2 is not
required.)
2. Remove access panel.
2. Remove 4 screws holding wire basket to top cover.
3. Remove information plate.
3. Lift wire basket from unit.
4. Disconnect fan motor wires and cut wire ties. Remove wires
from control box. Refer to unit wiring label. 4. Remove nuts holding fan motor to wire basket.
5. Remove screws holding top cover to coil grille and corner 5. Remove motor and fan blade assembly.
posts. 6. Pull wires through wire raceway to change motor.
6. Lift top cover from unit. 7. Reverse sequence for reassembly.
7. Reverse sequence for reassembly. 8. Prior to applying power, check that fan rotates freely.

Base and Comfort Series AC Control Box Base and Comfort HP Control Box
Fig. 4 – Base and Comfort Series Control Box Identification

9
Labeling
The wiring schematic, sub--cooling charging tables with
instructions, and warning labels. Refer to Fig. 5 for label location.

Fig. 5 – Figure Labels

10
ELECTRICAL Contactor
The contactor provides a means of applying power to unit using
! WARNING low voltage (24v) from transformer in order to power contactor
coil. Depending on unit model, you may encounter single-- or
ELECTRICAL SHOCK HAZARD double--pole contactors. Exercise extreme caution when
troubleshooting as 1 side of line may be electrically energized. The
Failure to follow this warning could result in personal contactor coil is powered by 24vac. If contactor does not operate:
injury or death.
1. With power off, check whether contacts are free to move.
Exercise extreme caution when working on any electrical Check for severe burning or arcing on contact points.
components. Shut off all power to system prior to
2. With power off, use ohmmeter to check for continuity of
troubleshooting. Some troubleshooting techniques require
coil. Disconnect leads before checking. A low resistance
power to remain on. In these instances, exercise extreme
reading is normal. Do not look for a specific value, as
caution to avoid danger of electrical shock. ONLY
TRAINED SERVICE PERSONNEL SHOULD different part numbers will have different resistance values.
PERFORM ELECTRICAL TROUBLESHOOTING. 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
Aluminum Wire voltage at coil with voltmeter. Reading should be between
20v and 30v. Contactor should pull in if voltage is correct
and coil is good. If contactor does not pull in, replace
! CAUTION contactor.
4. With high--voltage power off and contacts pulled in, check
UNIT OPERATION AND SAFETY HAZARD for continuity across contacts with ohmmeter. A very low or
Failure to follow this caution may result in equipment 0 resistance should be read. Higher readings could indicate
damage or improper operation. burned or pitted contacts which may cause future failures.
Aluminum wire may be used in the branch circuit (such as
the circuit between the main and unit disconnect), but only
copper wire may be used between the unit disconnect and
the unit.
Whenever aluminum wire is used in branch circuit wiring with this
unit, adhere to the following recommendations.
Connections must be made in accordance with the National
Electrical Code (NEC), using connectors approved for aluminum
wire. The connectors must be UL approved (marked Al/Cu with
the UL symbol) for the application and wire size. The wire size
selected must have a current capacity not less than that of the
copper wire specified, and must not create a voltage drop between
service panel and unit in excess of 2 of unit rated voltage. To
prepare wire before installing connector, all aluminum wire must
be “brush--scratched” and coated with a corrosion inhibitor such as
Pentrox A. When it is suspected that connection will be exposed to
moisture, it is very important to cover entire connection completely
to prevent an electrochemical action that will cause connection to
fail very quickly. Do not reduce effective size of wire, such as
cutting off strands so that wire will fit a connector. Proper size
connectors should be used. Check all factory and field electrical
connections for tightness. This should also be done after unit has
reached operating temperatures, especially if aluminum conductors
are used.

11
Capacitor Sometimes under adverse conditions, a standard run capacitor in a
system is inadequate to start compressor. In these instances, a start
! WARNING assist device is used to provide an extra starting boost to
compressor motor. This device is called a positive temperature
coefficient (PTC) or start thermistor. It is a resistor wired in parallel
ELECTRICAL SHOCK HAZARD with the run capacitor. As current flows through the PTC at
Failure to follow this warning could result in personal start--up, it heats up. As PTC heats up, its resistance increases
injury or equipment damage. greatly until it effectively lowers the current through itself to an
Capacitors can store electrical energy when power is off. extremely low value. This, in effect, removes the PTC from the
Electrical shock can result if you touch the capacitor circuit.
terminals and discharge the stored energy. Exercise extreme After system shutdown, resistor cools and resistance value returns
caution when working near capacitors. With power off, to normal until next time system starts. Thermistor device is
discharge stored energy by shorting across the capacitor adequate for most conditions, however, in systems where off cycle
terminals with a 15,000--ohm, 2--watt resistor. is short, device cannot fully cool and becomes less effective as a
start device. It is an easy device to troubleshoot. Shut off all power
NOTE: If bleed resistor is wired across start capacitor, it must be
to system.
disconnected to avoid erroneous readings when ohmmeter is
applied across capacitor. (S) Check thermistor with ohmmeter as described below. Shut off all
power to unit. Remove PTC from unit. Wait at least 10 minutes for
! WARNING PTC to cool to ambient temperature.
Measure resistance of PTC with ohmmeter.
ELECTRICAL SHOCK HAZARD The cold resistance (RT) of any PTC device should be
approximately 100--180 percent of device ohm rating.
Failure to follow this warning could result in personal
injury or equipment damage. 12.5--ohm PTC = 12.5--22.5 ohm resistance (beige color)
If PTC resistance is appreciably less than rating or more than 200
Always check capacitors with power off. Attempting to
percent higher than rating, device is defective.
troubleshoot a capacitor with power on can be dangerous.
Defective capacitors may explode when power is applied.
Insulating fluid inside is combustible and may ignite,
causing burns.
Capacitors are used as a phase--shifting device to aid in starting
certain single--phase motors. Check capacitors as follows:
1. With power off, discharge capacitors as outlined above.
Disconnect capacitor from circuit. Put ohmmeter on R X
10k scale. Using an analog ohmmeter, check each terminal
to ground (use capacitor case). Discard any capacitor which
measures 1/2 scale deflection or less. Place ohmmeter leads
across capacitor and place on R X 10k scale. Meter should
jump to a low resistance value and slowly climb to higher
value. Failure of meter to do this indicates an open
capacitor. If resistance stays at 0 or a low value, capacitor is A94006
internally shorted. Fig. 6 – Capacitors
2. Capacitance testers are available which will read value of Cycle Protector
capacitor. If value is not within ±10 percent value stated on
capacitor, it should be replaced. If capacitor is not open or Carrier thermostats have anti--cycle protection built in to protect the
shorted, the capacitance value is calculated by measuring compressor. Should a non--Carrier stat be utilized, it is
voltage across capacitor and current it draws. recommended to add a cycle protector to the system. Solid--state
cycle protector protects unit compressor by preventing short

WARNING
cycling. After a system shutdown, cycle protector provides for a 5
! ± 2--minute delay before compressor restarts. On normal start--up, a
5--minute delay occurs before thermostat closes. After thermostat
ELECTRICAL SHOCK HAZARD closes, cycle protector device provides a 3--sec delay.
Failure to follow this warning could result in personal Cycle protector is simple to troubleshoot. Only a voltmeter capable
injury or death. of reading 24v is needed. Device is in control circuit, therefore,
Exercise extreme caution when taking readings while power troubleshooting is safe with control power (24v) on and
is on. high--voltage power off.
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
all protective devices in series with Y terminal are closed.
3. Remove any capacitor that shows signs of bulging, dents, or Voltmeter should read 24v across T1 and T3. With 24v still
leaking. Do not apply power to a defective capacitor as it applied, move voltmeter leads to T2 and T3. After 5 ± 2 minutes,
may explode. voltmeter should read 24v, indicating control is functioning
normally. If no time delay is encountered or device never times out,
change control.

12
Crankcase Heater Pressure Switches
Crankcase heater is a device for keeping compressor oil warm. By Pressure switches are protective devices wired into control circuit
keeping oil warm, refrigerant does not migrate to and condense in (low voltage). They shut off compressor if abnormally high or low
compressor shell when the compressor is off. This prevents flooded pressures are present in the refrigeration circuit. Puron pressure
starts which can damage compressor. switches are specifically designed to operate with Puronr systems.
On units that have a single--pole contactor, the crankcase heater is R--22 pressure switches must not be used as replacements for the
wired in parallel with contactor contacts and in series with Puronr air conditioner or heat pump. Puronr pressure switches are
compressor. (See Fig. 7.) When contacts open, a circuit is identified by a pink stripe down each wire.
completed from line side of contactor, through crankcase heater, Low--Pressure Switch (A/C Only)
through run windings of compressor, and to other side of line. The low--pressure switch is located on suction line and protects
When contacts are closed, there is no circuit through crankcase against low suction pressures caused by such events as loss of
heater because both leads are connected to same side of line. This charge, low airflow across indoor coil, dirty filters, etc. It opens on
allows heater to operate when system is not calling for cooling. a pressure drop at about 50 psig for Puron and about 27 for R22. If
The heater does not operate when system is calling for cooling. system pressure is above this, switch should be closed. To check
TEMP SWITCH switch:
CRANKCASE HTR
1. Turn off all power to unit.
BLK BLK BLK BLK 2. Disconnect leads on switch.
3. Apply ohmmeter leads across switch. You should have
continuity on a good switch.
11 21
NOTE: Because these switches are attached to refrigeration system
A97586 under pressure, it is not advisable to remove this device for
Fig. 7 – Wiring for Single--Pole Contactor troubleshooting unless you are reasonably certain that a problem
The crankcase heater is powered by high--voltage power of unit. exists. If switch must be removed, remove and recover all system
Use extreme caution troubleshooting this device with power on. charge so that pressure gauges read 0 psi. Never open system
The easiest method of troubleshooting is to apply voltmeter across without breaking vacuum with dry nitrogen.
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
! CAUTION
method as absolute evidence heater is functioning. If compressor
has been running, the area will still be warm. PERSONAL INJURY HAZARD
With power off and heater leads disconnected, check across leads Failure to follow this caution may result in personal injury.
with ohmmeter. Do not look for a specific resistance reading. Wear safety glasses, protective clothing, and gloves when
Check for resistance or an open circuit. Change heater if an open handling refrigerant.
circuit is detected.
Time--Delay Relay To replace switch:
The TDR is a solid--state control, recycle delay timer which keeps 1. Apply heat with torch to solder joint and remove switch.
indoor blower operating for 90 sec after thermostat is satisfied.
This delay enables blower to remove residual cooling in coil after
compression shutdown, thereby improving efficiency of system.
! CAUTION
The sequence of operation is that on closure of wall thermostat and
PERSONAL INJURY HAZARD
at end of a fixed on delay of 1 sec, fan relay is energized. When
thermostat is satisfied, an off delay is initiated. When fixed delay of Failure to follow this caution may result in personal injury.
90 ± 20 sec is completed, fan relay is de--energized and fan motor Wear safety glasses when using torch. Have quenching
stops. If wall thermostat closes during this delay, TDR is reset and cloth available. Oil vapor in line may ignite when switch is
fan relay remains energized. TDR is a 24v device that operates removed.
within a range of 15v to 30v and draws about 0.5 amps. If the
blower runs continuously instead of cycling off when the fan 2. Braze in 1/4--in. flare fitting and screw on replacement
switch is set to AUTO, the TDR is probably defective and must be pressure switch.
replaced.

13
High--Pressure Switch (AC & HP) Tech Assist
The high--pressure switch is located in liquid line and protects The TechAssist is a service board incorporated in the outdoor unit.
against excessive condenser coil pressure. It opens around 610 psig The Tech Assist board is found on Comfort Series AC units built
for Puron and 400 psig for R22 (+/-- 10 for both). Switches close before March, 2008. It incorporates a series of LED’s to identify
at 298 (+/-- 20) psig for R--22 and 420 (+/-- 25) psig for Puron. components that have power through them. These components
High pressure may be caused by a dirty condenser coil, failed fan include both high and low voltage. Low voltage components
motor, or condenser air re--circulation. indicated are 24 volts, low pressure switch and high pressure
To check switch: switch. The high voltage components indicated are 230 volts,
1. Turn off all power to unit. contactor and compressor.
2. Disconnect leads on switch. Troubleshooting using the Tech Assist should reduce service time
as it quickly identifies where a problem may exist using a
3. Apply ohmmeter leads across switch. You should have
hopscotch method.
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
! WARNING
troubleshooting unless you are reasonably certain that a problem
ELECTRICAL SHOCK 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 warning could result in personal
without breaking vacuum with dry nitrogen. injury or possible equipment damage.
This tool does not replace the necessity to utilize proper
! CAUTION service meters. Always verify power is removed before
servicing equipment.

PERSONAL INJURY HAZARD The Tech Assist does not lock out any components and has no
effect on operation. It simply provides indication of power with
Failure to follow this caution may result in personal injury.
closed contacts or completed circuit through particular
Wear safety glasses, protective clothing, and gloves when components.
handling refrigerant.

To replace switch:
1. Apply heat with torch to solder joint and remove switch.

! CAUTION
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal injury.
Wear safety glasses when using torch. Have quenching
cloth available. Oil vapor in line may ignite when switch is
removed.

2. Braze in 1/4--in. flare fitting and replace pressure switch.

Loss of Charge Switch (HP Only)
Located on liquid line of heat pump only, the liquid line pressure
switch functions similar to conventional low--pressure switch.
Because heat pumps experience very low suction pressures during
normal system operation, a conventional low--pressure switch
cannot be installed on suction line. This switch is installed in liquid
line instead and acts as loss--of--charge protector. The liquid--line is
the low side of the system in heating mode. It operates identically
to low--pressure switch except it opens at 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
 Table 3—TechAssistt Diagnostics--at--a--Glance

LED Description ON OFF

Y . . . . . . . . . Thermostat cooling call . . . . . . . . Yes . . . . . . No
HPS . . . . . . . High Pressure Switch . . . . . . . . . Closed . . . Open
LPS . . . . . . . Low Pressure Switch . . . . . . . . . . Closed . . . Open CONTROL LPS
Y HPS

230V . . . . . . AC Line Power Available . . . . . . Yes . . . . . . No POWER

Contactor . . Contactor Energized . . . . . . . . . . Yes . . . . . . No 230V Contactor Compressor
Compressor . Compressor Running . . . . . . . . . . Yes . . . . . . No
Note: Follow arrows to first unlit LED in control (green) ladder or power (amber) ladder to determine problem area.
For contactor LED to be On, all control LEDs (green) as well as 230V LED (amber) must already be on, and contactor must operate
properly
Control Ladder Power ladder
Green LEDs Amber LEDs Indication Possible Cause & Quick
Contac- Trouble---Shooting
Y HPS LPS 230V Compressor
tor
--- No 230V power to unit --- Check 230V disconnect/ circuit breaker
Off Off Off Off Off Off
--- No thermostat call --- Check 230V L1 & L2 wire connections
--- Check pressures
On Off Off --- --- Off Off --- HPS Switch Open
--- Check HPS wire connections
--- Check pressures
On On Off --- --- Off Off --- LPS Switch Open
--- Check LPS wire connections
--- Check 230V disconnect / circuit breaker
On On On Off Off Off --- No 230V power to unit
--- Check 230V L1 & L2 wire connections
--- Check Contactor and replace if necessary
On On On On Off Off --- Contactor open ***
--- Check contactor wire connections
--- Check for compressor protector trip, capacitor
On On On On On Off --- Compressor not running* fault, faulty connections or compressor fault.
SEE BELOW.
On On On On On On --- Compressor running --- OK

Off Off Off On Off Off --- No thermostat call, standby --- OK
--- Contactor stuck closed, --- Check Contactor and replace if necessary
Off Off Off On On Off
compressor tripped --- Check wire connections for shorts
--- Contactor stuck closed, --- Check Contactor and replace if necessary
Off Off Off On On On
compressor running --- Check wire connections for shorts
*Compressor not running: If all LEDs are on except the Compressor, this indicates that power is applied to the compressor but it is not running. Check the
following sequence:
1) Check all compressor wire connections
2) Check run capacitor and replace if necessary
3) Try starting compressor
4) If compressor LED does not come on, then leave unit in standby for up to four hours to allow thermal protector to reset, and all pressures to equalize
5) Try starting the compressor again
6) If compressor LED comes on, then turns off quickly, investigate starting issues such as low line voltage
7) If compressor LED never comes on, compressor may be faulty.

Fig. 8 – Tech Assist Ladder Diagram

15
 FEEDER TUBE HK32EA001 Defrost Control
STUB TUBE The HK32EA001 defrost control is used in all Base series heat
pump models 25HBA and 25HBR. Its features include selectable
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.
Circuit R--O energizes reversing valve switching it to cooling
position. Circuit R--Y sends low voltage through the safeties and
DEFROST energizes the contactor, which starts the compressor and energizes
THERMOSTAT the T1 terminal on the circuit board. This will energize the OF2 fan
A97517 relay which starts the outdoor fan motor.
Fig. 9 – Defrost Thermostat Location When the cycle is complete, R--Y is turned off and compressor and
outdoor fan should stop. With Carrier thermostats, the O terminal
Defrost Thermostats remains energized in the cooling mode. If the mode is switched to
Defrost thermostat signals heat pump that conditions are right for heat or Off, the valve is de--energized. There is no compressor
defrost or that conditions have changed to terminate defrost. It is a delay built into this control.
thermally actuated switch clamped to outdoor coil to sense its Heating Sequence of Operation
temperature. Normal temperature range is closed at 30_ ± 3_F and
open at 65_ ± 5_F. Defrost thermostats are used in Base and On a call for heating, thermostat makes R--Y, and R--G. Circuit
Comfort models, a coil temperature thermistor is used in Preferred R--Y sends low voltage through the safeties and energizes the
and Infinity series units. contactor, which starts the compressor and energizes the T1
terminal on the circuit board. The T1 terminal energizes the defrost
Check Defrost Thermostat logic. This will energize the OF2 fan relay start the outdoor motor.
There is a liquid header with a brass distributor and feeder tube The T1 terminal must be energized for defrost to function.
going into outdoor coil. At the end of 1 of the feeder tubes, there is When the cycle is complete, R--Y is turned off and the compressor
a 3/8--in. OD stub tube approximately 3 in. long. (See Fig. 9.) The and outdoor fan should stop. There is no compressor delay built
defrost thermostat should be located on stub tube. Note that there is into this control.
only 1 stub tube used with a liquid header, and on most units it is Defrost Sequence (HK32EA001)
the bottom circuit.
The defrost control is a time/temperature control that has field
NOTE: The defrost thermostat must be located on the liquid side selectable settings of 30, 60, and 90 minutes. These represent the
of the outdoor coil on the bottom circuit and as close to the coil as amount of time that must pass after closure of the defrost
possible. thermostat before the defrost sequence begins.
Defrost Control Board The defrost thermostat senses coil temperature throughout the
Troubleshooting defrost control involves a series of simple steps heating cycle. When the coil temperature reaches the defrost
that indicate whether or not board is defective. thermostat setting of approximately 32ºF, it will close, which
NOTE: This procedure allows the service technician to check energizes the DFT terminal and begins the defrost timing sequence.
When the DTF has been energized for the selected time, the defrost
control board and defrost thermostat for defects. First, troubleshoot
cycle begins, and the control shifts the reversing valve into cooling
to make sure unit operates properly in heating and cooling modes.
position, and turns the outdoor fan off. This shifts hot gas flow into
This ensures operational problems are not attributed to the defrost
the outdoor coil which melts the frost from the coil. The defrost
control board. cycle is terminated when defrost thermostat opens at approximately
65ºF, or automatically after 10 minutes.

OUTDOOR FAN
RELAY
HK32EA001

DEFROST THERMOSTAT
MUST BE CLOSED BEFORE
DEFROST TIMER BEGINS

T1 - ENABLES DEFROST Y OUTPUT TO PRESSURE

TIMER. MUST BE SWITCHES AND CONTACTOR
ENERGIZED FOR
DEFROST TIMER
TO START

C - COMMON

O - REVERSING VALVE

SPEEDUP

THERMOSTAT INPUTS

A05332
Fig. 10 – HK32EA001 Defrost Control

16
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 4.)
4. When defrost begins, it will continue until the defrost Table 4—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
of defrost cycle time. the control board will occur.
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.

17
 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 Sequence of operation
for more accurate reading. On power--up (24 volts between R--C) the 5 minute cycle timer
3. Turn on power to outdoor unit. begins counting down. The compressor will not be energized until
4. Restart unit in heating. this timer is elapsed.
5. Within a few minutes, liquid line temperature drops within a Cooling
range causing defrost thermostat contacts to close. On a call for cooling, thermostat makes R--O, R--Y, and R--G.
Temperature range is from 33_F to 27_F. Notice Circuit R--O energizes reversing valve switching it to cooling
temperature at which ohmmeter reading goes from ∞ to zero position. Circuit R--Y sends low voltage through the safeties and
ohms. Thermostat contacts close at this point. energizes the T1 terminal on the circuit board. If the compressor
6. Short between the speed--up terminals using a small slotted has been off for 5 minutes, or power has not been cycled for 5
screwdriver. minutes, the OF2 relay and T2 terminal will energize. This will
7. Unit changes over to defrost within 21 sec (depending on close the contactor, start the outdoor fan motor and compressor.
timing cycle setting). Liquid line temperature rises to range When the cycle is complete, R--Y is turned off and compressor and
where defrost thermostat contacts open. Temperature range outdoor fan should stop. When using Carrier thermostats, the
is from 60_F to 70_F. Resistance goes from zero to ∞ when reversing valve remains energized in the cooling mode until the
contacts are open. thermostat is switched to heat, or the mode it turned off. The
8. If either opening or closing temperature does not fall within 5--minute time guard begins counting. Compressor will not come
above ranges or thermostat sticks in 1 position, replace on again until this time delay expires. In the event of a power
thermostat to ensure proper defrost operation. interruption, the time guard will not allow another cycle for 5
minutes.
NOTE: With timing cycle set at 90 minutes, unit initiates defrost
within approximately 21 sec. When you hear the reversing valve Heating
changing position, remove screwdriver immediately. Otherwise, On a call for heating, thermostat makes R--Y, and R--G. Circuit
control will terminate normal 10--minute defrost cycle in R--Y sends low voltage through the safeties and energizes the T1
approximately 2 sec. terminal on the circuit board. T1 energizes the defrost logic circuit.
If the compressor has been off for 5 minutes, or power has not been
cycled for 5 minutes, the OF2 relay and T2 terminal will energize.
T2 C C O

This will close the contactor, start the outdoor fan motor and
OF1

compressor.
OF2
DFT

When the cycle is complete, R--Y is turned off and the compressor
O R W2 Y C

T1

and outdoor fan should stop. The 5 minute time guard begins
counting. Compressor will not come on again until this time delay
expires. In the event of a power interruption, the time guard will
Y

not allow another cycle for 5 minutes.

P1

Defrost Sequence
SPEEDUP

60
30
INTERVAL TIMER OFF
J1

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

120
90
30
60

selectable settings of 30, 60, 90 and 120 minutes. These represent

P3
DFT

the amount of time that must pass after closure of the defrost
ON
SHIFT
QUIET

HK32EA003 thermostat before the defrost sequence begins.

The defrost thermostat senses coil temperature throughout the
Speedup Quiet Defrost interval
Pins Shift DIP switches heating cycle. When the coil temperature reaches the defrost
A05378 thermostat setting of approximately 32 degrees F, it will close,
Fig. 11 – HK32EA003 Defrost Control which energizes the DFT terminal and begins the defrost timing
HK32EA003 Defrost Control sequence. When the DTF has been energized for the selected time,
the defrost cycle begins. If the defrost thermostat opens before the
The HK32EA003 defrost control is used in all 25HCA Comfort
timer expires, the timing sequence is reset.
Series heat pumps with Puron refrigerant. Its features include
selectable defrost intervals of 30, 60, 90, & 120 minutes, Quiet Defrost cycle is terminated when defrost thermostat opens or
Shift, compressor time delay, deluxe defrost speed up capability. automatically after 10 minutes.
This section describes the sequence of operation and trouble
shooting methods for this control.

18
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.
ELECTRICAL SHOCK HAZARD
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
be turned off for two 30 second intervals as explained previously. injury 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).

19
COPELAND SCROLL Compressor Failures
COMPRESSOR Compressor failures are classified in 2 broad failure categories;
mechanical and electrical. Both types are discussed below.
Mechanical Failures
A compressor is a mechanical pump driven by an electric motor
Scroll Gas Flow contained in a welded or hermetic shell. In a mechanical failure,
Compression in the scroll is
motor or electrical circuit appears normal, but compressor does not
created by the interaction of function normally.
an orbiting spiral and a
stationary spiral. Gas enters

! WARNING
an outer opening as one of the
spirals orbits. 1

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death.
Do not supply power to unit with compressor terminal box
cover removed.
2 3

! WARNING
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.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death.
Exercise extreme caution when reading compressor currents
when high--voltage power is on. Correct any of the
4 5
problems described below before installing and running a
replacement compressor.
By the time the gas arrives at Actually, during operation, all
the center port, discharge six gas passages are in various
pressure has been reached. stages of compression at all
times, resulting in nearly con- Locked Rotor
tinuous suction and discharge.
In this type of failure, compressor motor and all starting
components are normal. When compressor attempts to start, it
draws locked rotor current and cycles off on internal protection.
A90198
Locked rotor current is measured by applying a clamp--on ammeter
Fig. 12 – Scroll Compressor Refrigerant Flow around common (blk) lead of compressor. Current drawn when it
The compressors used in these products are specifically designed to attempts to start is then measured. Locked rotor amp (LRA) value
operate with designated refrigerant and cannot be interchanged. is stamped on compressor nameplate.
The compressor is an electrical (as well as mechanical) device. If compressor draws locked rotor amps and all other external
Exercise extreme caution when working near compressors. Power sources of problems have been eliminated, compressor must be
should be shut off, if possible, for most troubleshooting techniques. replaced. Because compressor is a sealed unit, it is impossible to
Refrigerants present additional safety hazards. determine exact mechanical failure. However, complete system
should be checked for abnormalities such as incorrect refrigerant
! CAUTION charge, restrictions, insufficient airflow across indoor or outdoor
coil, etc., which could be contributing to the failure.
PERSONAL INJURY HAZARD Runs, Does Not Pump
Failure to follow this caution may result in personal injury. In this type of failure, compressor motor runs and turns
compressor, but compressor does not pump refrigerant. A
Wear safety glasses, protective clothing, and gloves when clamp--on ampmeter on common leg shows a very low current
handling refrigerant. draw, much lower than rated load amp (RLA) value stamped on
compressor nameplate. Because no refrigerant is being pumped,
The scroll compressor pumps refrigerant through the system by the there is no return gas to cool compressor motor. It eventually
interaction of a stationary and an orbiting scroll. (See Fig. 12.) The overheats and shuts off on its internal protection.
scroll compressor has no dynamic suction or discharge valves, and
it is more tolerant of stresses caused by debris, liquid slugging, and
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.

20
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.

21
 (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
of compressor motor terminal identification. injury.
Single--Phase Motors Use caution when working near compressor terminals.
To identify terminals C, S, and R: Damaged terminals have the potential to cause personal
injury.
1. Turn off all unit power.
2. Discharge run and start capacitors to prevent shock. Never put face or body directly in line with terminals.
3. Remove all wires from motor terminals.
4. Read resistance between all pairs of terminals using an To determine if any winding has a break in the internal wires and
ohmmeter on 0--10 ohm scale. current is unable to pass through, follow these steps:
5. Determine 2 terminals that provide greatest resistance 1. Be sure all power is off.
reading. 2. Discharge all capacitors.
Through elimination, remaining terminal must be common (C). 3. Remove wires from terminals C, S, and R.
Greatest resistance between common (C) and another terminal
4. Check resistance from C--R, C--S, and R--S using an
indicates the start winding because it has more turns. This terminal ohmmeter on 0--1000 ohm scale.
is the start (S). The remaining terminal will be run winding (R).
Because winding resistances are usually less than 10 ohms, each
NOTE: If compressor is hot, allow time to cool and internal line reading appears to be approximately 0 ohm. If resistance remains at
break to reset. There is an internal line break protector which must 1000 ohms, an open or break exists and compressor should be
be closed. replaced.
All compressors are equipped with internal motor protection. If
motor becomes hot for any reason, protector opens. Compressor
should always be allowed to cool and protector to close before ! CAUTION
troubleshooting. Always turn off all power to unit and disconnect
leads at compressor terminals before taking readings. UNIT DAMAGE HAZARD
Most common motor failures are due to either an open, grounded, Failure to follow this caution may result in equipment
or short circuit. When a compressor fails to start or run, 3 tests can damage or improper operation.
help determine the problem. First, all possible external causes Be sure internal line break overload is not temporarily open.
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.

22
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
3. Be sure all power is off. injury 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
5. Remove wires from terminals C, S, and R.
this 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
8. If reading of 0 or low resistance is obtained, motor is heat from one replace to another. The condenser is the outdoor coil
grounded. Replace compressor. in the cooling mode and the evaporator is the indoor coil.
Compressor resistance to ground should not be less than 1000 In a heat pump, the condenser is the indoor coil in the heating
ohms per volt of operating voltage. mode and the evaporator is the outdoor coil.
Example: In the typical air conditioning mode, compressed hot gas leaves the
230 volts X 1000 ohms/volt = 230,000 ohms minimum. compressor and enters the condensing coil. As gas passes through
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.
3. Resistance measuring instrument must have an accuracy UNIT DAMAGE HAZARD
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
Make This Critical Test much water as other oils designed for HCFC and CFC
(Not advisable unless above conditions are met) refrigerants. Take all necessary precautions to avoid
exposure of the oil to the atmosphere. (See Table 5.)
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.

23
 Table 5—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 38 3MAF--- POE
PURON--- 2 STAGE ZPS30, ZPS40 34 3MAF--- POE
PURON--- 2 STAGE ZPS51 62 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.

24
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 Wear safety glasses, protective clothing, and gloves when
injury or equipment damage. handling refrigerant.

Never attempt to make repairs to existing service valves. Pumpdown Procedure

Unit operates under high pressure. Damaged seats and Service valves provide a convenient shutoff valve useful for certain
o--rings should not be replaced. Replacement of entire refrigeration--system repairs. System may be pumped down to
service valve is required. Service valve must be replaced by make repairs on low side without losing complete refrigerant
properly trained service technician.
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.

25
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 and Comfort Puron Heat Pumps.
sealing surface. If retainer does not pull out easily, carefully
use locking pliers to remove it.
TEFLONr SEAL
5. Slide piston and piston ring out by inserting a small soft
wire with small kinks through metering hole. Do not
damage metering hole, sealing surface around piston cones, PISTON
or fluted portion of 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 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)

26
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 COIL ON OUTDOOR COIL
TO OUTDOOR SERVICE VALVE ON
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)

27
Liquid Line Filter Drier
Filter driers are specifically designed for R--22 or Puronr Install Liquid--line Filter Drier Indoor -- HP
refrigerant. Only operate with the appropriate drier using factory Refer to Fig. 24 and install filter drier as follows:
authorized components.
1. Braze 5 in. liquid tube to the indoor coil.
It is recommended that the liquid line drier be installed at the
indoor unit. Placing the drier near the TXV allows additional 2. Wrap filter drier with damp cloth.
protection to the TXV as the liquid line drier also acts as a strainer. 3. Braze filter drier to 5 in. long liquid tube from step 1.
4. Connect and braze liquid refrigerant tube to the filter drier.
Install Liquid--line Filter Drier Indoor -- AC Suction Line Filter Drier
The suction line drier is specifically designed to operate with
! CAUTION Puronr, use only factory authorized components. Suction line filter
drier is used in cases where acid might occur, such as burnout. Heat
UNIT DAMAGE HAZARD pump units must have the drier installed between the compressor
and accumulator only. Remove after 10 hours of operation. Never
Failure to follow this caution may result in equipment damage
leave suction line filter drier in a system longer than 72 hours
or improper operation.
(actual time).
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.

A05227
A05178 Fig. 24 – Liquid Line Filter Drier -- HP
Fig. 23 – Liquid Line Filter Drier -- AC

28
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
Wear safety glasses, protective clothing, and gloves when
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 5.)
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

29
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 function properly.
on suction tube at outlet of evaporator coil. This
temperature is converted into pressure by refrigerant in the
bulb pushing downward on the diaphragm which opens the
valve via the 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
5. Install TXV on indoor coil liquid line. Sweat swivel adapter
works against the spring pressure and evaporator suction
to inlet of indoor coil and attach to TXV outlet. Use backup
pressure to open the valve.
wrench to avoid damage to tubing or valve. Sweat inlet of
If the load increases, the temperature increases at the bulb,
TXV, marked “IN” to liquid line. Avoid excessive heat
which increases the pressure on the top side of the
which could damage valve.
diaphragm. This opens the valve and increases the flow of
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
clamps provided. Insulate bulb with field--supplied
The thermostatic expansion valve is specifically designed to
insulation tape. See Fig. 26 for correct positioning of
operate with a refrigerant type. Do not use an R--22 TXV on a
sensing bulb.
Puron system, and do not use a Puron valve on an R--22 system.
Refer to Product Data Sheet for the appropriate TXV kit number. 9. Proceed with remainder of unit installation.
10 O’CLOCK

! CAUTION 2 O’CLOCK

SENSING BULB

UNIT OPERATION HAZARD

STRAP
Failure to follow this caution may result in equipment
damage or improper operation.
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

30
Replacing TXV on an Indoor Coil (pre--2006) 11. Route equalizer tube through suction connection opening
1. Pump system down to 2 psig and recover refrigerant. (large hole) in fitting panel and install fitting panel in place.
2. Remove coil access panel and fitting panel from front of 12. Sweat inlet of TXV, marked “IN” to liquid line. Avoid
cabinet. excessive heat which could damage valve.
3. Remove TXV support clamp using a 5/16--in. nut driver. 13. Proceed with remainder of unit installation.
Save the clamp.
4. Remove R--22 TXV using a backup wrench on flare Make Piping Connections
connections to prevent damage to tubing.
5. Using wire cutters, cut equalizer tube off flush with vapor
tube inside cabinet.
! WARNING
6. Remove bulb from vapor tube inside cabinet. PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
7. Braze equalizer stub--tube closed. Use protective barrier as
necessary to prevent damage to drain pan. Failure to follow this warning could result in personal
IMPORTANT: Route the equalizer tube of TXV through injury or death.
suction line connection opening in fitting panel prior to Relieve pressure and recover all refrigerant before
replacing fitting panel around tubing. system repair or final unit disposal.
8. Install TXV with 3/8--in. copper tubing through small hole Use all service ports and open all flow--control
in service panel. Use wrench and backup wrench, to avoid devices, including solenoid valves.
damage to tubing or valve, to attach TXV to distributor.
9. Reinstall TXV support clamp (removed in item 3).
10. Attach TXV bulb to vapor tube inside cabinet, in same ! CAUTION
location as original was when removed, using supplied bulb
clamps (nylon or copper). See Fig. 26 for correct UNIT DAMAGE HAZARD
positioning of sensing bulb. Failure to follow this caution may result in equipment
11. Route equalizer tube through suction connection opening damage or improper operation.
(large hole) in fitting panel and install fitting panel in place. Do not leave system open to atmosphere any longer than
12. Sweat inlet of TXV, marked “IN” to liquid line. Avoid minimum required for installation. POE oil in compressor is
excessive heat which could damage valve. extremely susceptible to moisture absorption. Always keep
13. Install vapor elbow with equalizer adapter to vapor line of ends of tubing sealed during installation.
line set and vapor connection to indoor coil. Adapter has a
1/4--in. male connector for attaching equalizer tube.
14. Connect equalizer tube of TXV to 1/4--in. equalizer fitting
! CAUTION
on vapor line adapter. Use backup wrench to prevent UNIT DAMAGE HAZARD
damage to equalizer fitting.
Failure to follow this caution may result in equipment
15. Proceed with remainder of unit installation. damage or improper operation.
Replacing TXV on Indoor Coil (post--2006) If ANY refrigerant tubing is buried, provide a 6 in. vertical
1. Pump system down to 2 psig and recover refrigerant. rise at service valve. Refrigerant tubing lengths up to 36 in.
may be buried without further special consideration. Do
2. Remove coil access panel and fitting panel from front of not bury lines longer than 36 in.
cabinet.
3. Remove TXV support clamp using a 5/16--in. nut driver. Save
the clamp (N coils only).
4. Remove TXV using a backup wrench on connections to
prevent damage to tubing.
COIL
5. Remove equalizer tube from suction line of coil. SENSING
Note: Some coils may have a mechanical connection. If coil BULB
has a braze connection, use file or tubing cutter to cut brazed
EQUALIZER
equalizer line approximately 2 inches above suction tube. TUBE
6. Remove bulb from vapor tube inside cabinet.
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
EXPANSION
only.) VALVE
9. Attach equalizer tube to suction line. If coil has mechanical A91277
connection, then use wrench and back up wrench to attach. If Fig. 27 – Typical TXV Installation
coil has brazed connection, use file or tubing cutters to 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
clamps (nylon or copper). See Fig. 26 for correct positioning
of sensing bulb.

31
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.

32
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.
2. Drain any trapped oil from accumulator if used.
Failure to follow this caution may result in personal injury.
3. Remove and discard liquid--line strainer and filter drier.
Wear safety glasses, protective clothing, and gloves when
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
compressor and accumulator.
2. Remove and recover all refrigerant from system until
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
driers must be replaced, retest pressure drop after additional
3. Disconnect electrical leads from compressor. Disconnect or
10 hours (run time). Continue to monitor pressure drop
remove crankcase heater and remove compressor
across suction line filter drier. After 10 hr of run time,
hold--down bolts.
remove suction--line filter drier and replace liquid--line filter
4. Cut compressor from system with tubing cutter. Do not use drier. Never leave suction--line filter drier in system longer
brazing torch for compressor removal. Oil vapor may ignite than 72 hr (actual time).
when compressor is disconnected.
6. Charge system. (See unit information plate.)
5. Scratch matching marks on stubs in old compressor. Make

CAUTION
corresponding marks on replacement compressor.
6. Use torch to remove stubs from old compressor and to !
reinstall them in replacement compressor.
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

Failure to follow this caution may result in equipment
damage or improper operation.
Do not leave system open to atmosphere. Compressor oil is
highly susceptible to moisture absorption.

33
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
by adding or removing 0.6 oz/ft of 3/8 liquid line above or below
5000 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 are favorable, check system charge by subcooling method. If any
3500 SYSTEM
MICRONS

adjustment is necessary, adjust charge slowly and allow system to

3000
operate for 15 minutes to stabilize before declaring a properly
2500 charged system.
2000 If the indoor temperature is above 80_F (26.67_C), and the
1500 VACUUM TIGHT 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.
If the indoor temperature is below 70_F (21.11_C), or the outdoor
0 1 2 3 4 5 6 7
temperature is not in the favorable range, adjust charge for line set
MINUTES 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.
NOTE: If line length is beyond 80 ft (24.38 m) or greater than 20
The triple evacuation method should be used when vacuum pump
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: Troubleshooting with SuperHeat
1. Pump system down to 28 in. of mercury and allow pump to This troubleshooting routine was developed to diagnose cooling
continue operating for an additional 15 minutes. problems using superheat in TXV systems. It is effective on heat
2. Close service valves and shut off vacuum pump. pumps in cooling mode as well as air conditioners. The system
3. Connect a nitrogen cylinder and regulator to system and must utilize a TXV as the expansion device in cooling mode.
open until system pressure is 2 psig. Basic Diagnostics
4. Close service valve and allow system to stand for 1 hr. NOTE: When checking refrigerant charge and troubleshooting
During this time, dry nitrogen will be able to diffuse operating systems, the indoor airflow has significant effect on the
throughout the system absorbing moisture. determination. If you are at this stage, it is assumed you have
5. Repeat this procedure as indicated in Fig. 31. System will already checked the subcooling once and believe the charge is
then be free of any contaminants and water vapor. correct. From this point, the airflow must be verified prior to
proceeding, hence step 1 below.
EVACUATE
1. Check or verify proper indoor airflow
BREAK VACUUM WITH DRY NITROGEN S Indoor air filter
S Duct dampers and supply registers are open
WAIT
S Indoor coil for debris
EVACUATE 2. Check subcooling at OD unit liquid service valve
S Outdoor airflow (debris on coil, etc.)
BREAK VACUUM WITH DRY NITROGEN
S Set the subcooling at value listed on rating plate if
WAIT standard lineset
S Set the subcooling at the maximum of 10°F or value
EVACUATE listed on rating plate if a long line application
3. Check superheat at OD unit vapor service valve.
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM) S If low (< 2°F), proceed to Low SuperHeat section.
S If between 2 and 20°F/--6.7_C valve is probably
CHARGE SYSTEM operating properly.
A95425 S If greater than 20°F/--6.7_C, perform Pseudo Evaporator
Fig. 31 – Triple Evacuation Method SuperHeat Instructions check as follows:

34
 ⎯ Check refrigerant pressure at vapor service valve and S If OK proceed to Replace Valve
refrigerant temperature at outlet of evaporator. High Superheat with Normal or Low Pressure
⎯ Use suction line geometry (diameter and equivalent NOTE: Normal or low suction pressure is considered:
length), unit capacity and Tables 7 and 8 to determine R--22 < 80 psig, Puron < 135 psig.
suction pressure drop. 9. Check for restriction in liquid line (kinked line, filter drier
S For standard lineset diameters (vapor service restricted, etc.)
valve diameters and larger) and lengths (less than S If OK proceed to Step 10
80 ft), generally no pressure adjustment (per
10. Check for restriction in suction line (kink, restricted suction
Table 7 or 8) is required.
filter drier etc.))
S For longer (greater than 80 ft) and small diameter .
linesets (less than service valve size), correct
S If OK proceed to Step 11
pressure (add to gauge pressure reading) per 11. Check power element cap tube is not broken
Tables 7 and 8. S If OK proceed to Step 12
S If Pseudo Superheat is greater than 15, proceed to High 12. Check that equalizer tube is not kinked or plugged
SuperHeat section. S If OK proceed to Step 13
S If Pseudo Evaporator Superheat is between 2 and 15, 13. Check that inlet screen (R--22 systems) is not restricted
TXV appears to be functioning properly.
S If OK proceed to Step 14
S If operation erratic (hunting), proceed to Hunting
14. Replace Valve
Superheat °F Superheat in repetition section.
High Superheat with Normal or High Suction Pressure
NOTE: Hunting is when the valve superheat swings more than
NOTE: Normal to High suction pressure is considered
10_.
for R--22: > ∼65 psig, Puron: > ∼110 psig. An application issue or
Low Superheat with Normal or Low Suction Pressure other system component failure typically causes this condition.
NOTE: Normal or low suction pressure is considered for 15. Check airflow, sensing bulb tightness, orientation on vapor
R--22: < 80 psig, Puron: < 135 psig tube and ensure bulb is properly wrapped.
1. Re--check airflow and then check sensing bulb tightness, S If OK proceed to Step 16
orientation on vapor tube and is properly wrapped.
16. R--410A Systems: Make sure proper valve is used (Not
S Low Superheat with Normal or Low Suction Pressure R--22)
If OK proceed to Step 2
S If OK proceed to Step 17
2. Check superheat at Vapor Service Valve and Pseudo
Evaporator Superheat. 17. Check for even temperature distribution at outlet of each
circuit of evaporator
S If both are less than 2°F, TXV likely not controlling
properly, i.e. stuck open --> REPLACE VALVE S If OK proceed to Step 18
18. Check for high evaporator load: Return Air Leaks, high
S If superheat is higher than 15°F, proceed to Step 3 indoor wet bulb and/or dry bulb temp, undersized system,
3. Perform TXV function check. etc.
S With system running, place sensing bulb in ice bath for S If OK proceed to Step 19
∼1 minute --> superheat should increase.
19. Check that compressor is pumping properly
⎯ If no response, Replace Valve
S Loose Rule of Thumb: Is discharge saturated ∼20°F
⎯ If OK proceed to Step 4 higher than ambient temperature? Is discharge superheat
4. Check for even temperature distribution at outlet of each between 15_F and 50_F?
circuit of evaporator Hunting Superheat
S If greater than 15°F between circuits, distributor or coil NOTE: Hunting is when the valve superheat swings more than
has a restriction. 10°F Superheat in repetition. This is typically an application issue.
S If OK proceed to Step 5 20. Check for obvious kinked or pinched distributor (capillary)
Low Superheat with High Suction Pressure tubes causing imbalance to the circuiting.
NOTE: High suction pressure is considered for R--22: > ∼80 psig, S If OK proceed to Step 21
Puron: > ∼135 psig. An application issue or other system 21. Check that proper size valve is used per Product Literature.
component failure typically causes this condition. S If OK proceed to Step 22
5. R--22 Systems: Check that proper valve used (not an 22. Check airflow, sensing bulb tightness, orientation on vapor
R--410A valve) tube and ensure bulb is properly wrapped.
S If OK proceed to Step 6 S If OK proceed to Step 23
6. Check airflow, sensing bulb tightness, orientation on vapor 23. Check for even temperature distribution (±5° difference) at
tube and ensure bulb is properly wrapped. outlet of each circuit of evaporator and for even air
S If OK proceed to Step 7 distribution over all evaporator slabs
7. Check that compressor is pumping properly S If OK proceed to Step 24.
NOTE: Loose Rules of Thumb: Is discharge saturated ∼20°F 24. Move sensing bulb further down suction line.
higher than ambient temperature? Is discharge superheat between S If problem not corrected, replace valve
15 and 50?
S If OK proceed to Step 8
8. Recheck Airflow and Subcooling.

35
Pseudo Evaporator Superheat Instructions 1. Take suction line temperature at outlet of evaporator at
The Pseudo Evaporator Superheat calculates the superheat at the indoor unit.
outlet of the evaporator with known and available information. 2. Take suction service valve pressure at OD unit.
Because there generally is not a pressure port on the vapor line at 3. Determine lineset vapor line equivalent length and tube
the indoor coil, this procedure allows the service personnel to diameter.
evaluate the evaporator superheat with the vapor pressure port at 4. Determine suction line pressure drop from Table 7 (Puron)
the outdoor unit. or Table 8 (R--22).
The method requires the following information: 5. Calculate Pseudo Evaporator Superheat.
S Suction line temperature at the outlet of the evaporator S Add the suction line pressure drop to the pressure
(°F). reading obtained at suction service valve.
S Suction line pressure at the outdoor unit (psig). NOTE: For nominal and larger diameter vapor lines with standard
S Outdoor nominal unit size (btuh). length linesets (vapor line same size as service valve fitting size and
larger with equivalent length less than 80 ft) the pressure drop can
S Suction line equivalent line length (ft).
be ignored – use vapor service valve pressure and evaporator outlet
S Suction line pressure drop from tables (Table 7 and Table temperature to calculate superheat
8).
S Determine saturated evaporator temperature from a
S Pressure--Temperature relationship for refrigerant used refrigerant pressure temperature relationship chart (PT
(P--T Chart). chart).
If system uses a vapor line the same size as vapor service valve S Subtract saturated evaporator from evaporator suction
fitting or larger AND the line set equivalent length is 80 feet or
line temperature to obtain evaporator superheat.
less, the pressure drop in vapor line of line set can be ignored.

90° STD
90° LONG RAD 45° STD

A01058
Fig. 32 – Tube Fitting Geometry
Table 6—Fitting Losses in Equivalent Feet
TUBE SIZE OD FITTING --- REFERENCE DIAGRAM IN FIGURE 34
(IN.) 90° STD (A) 90° LONG RAD (B) 45° STD (C)
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

36
 Table 7—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
7, 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.

37
 Table 8—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 8, 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 8, 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

38
 Table 9—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 #N/A
112 37.2 218 75.1 324 101.6 430 122.2 536 139.3 676 #N/A
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

39
 Table 10—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

40
 Table 11—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

41
 Table 12—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

42
 Table 13—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

43
 Table 14—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

44
TWO--STAGE 25HNA/24ANA Model Plug
Each control board contains a model plug. The correct model plug
Application Guidelines must be installed in order for the system to operate properly. (See
Carrier designed and tested the two--stage air conditioner and heat Table 15.)
pump products with Puron refrigerant to operate at a minimum The model plug is used to identify the type and size of unit to the
outdoor operating ambient in cooling mode at 55_F without low control. On 25HNA6 models, the model plug is also used to
ambient cooling enabled and the maximum outdoor operating determine the start sequence timing for each individual model.
ambient in cooling is 125_F/51.6_C. On Infinity communicating
On new units, the model and serial numbers are inputted into the
systems, only low ambient cooling is available to 0_F/--17.8_C.
board’s memory at the factory. If a model plug is lost or missing at
The maximum outdoor operating ambient in heating mode is initial installation, the unit will operate according to the
66_F/18.8_C on all heat pumps. Continuous operation in heating information input at the factory and the appropriate error code will
mode is approved to --30_F/--34.4_C. Thermostat options for the flash temporarily. An RCD replacement board contains no model
two stage units are as follows: and serial information. If the factory control board fails, the model
S Bristol reciprocating two stage units can utilize either a plug must be transferred from the original board to the replacement
two stage thermostat or an Infinity communicating User board for the unit to operate.
Interface. NOTE: The model plug takes priority over factory model
S Copeland scroll two stage units must use the Infinity information input at the factory. If the model plug is removed after
communicating User Interface. initial power up, the unit will operate according to the last valid
25HNA9 Copeland scroll units require Infinity communicating model plug installed, and flash the appropriate fault code
User Interface (UI) to achieve the needed airflow for comfort and temporarily.
efficiency in both low and high stage. The Copeland scroll two Table 15—Model Plug Information
stage compressor unloads to 67% of full compressor capacity PIN RESISTANCE
verses the Bristol reciprocating two stage compressor that decreases MODEL
MODEL (K---ohms)
to about 50% of full capacity. PLUG
NUMBER
NUMBER
Indoor units for the two stage require variable speed indoor blower Pins 1---4 Pins 2---3
capabilities. Only unit combinations listed in the two stage 25HNA624 HK70EZ002 5.1 18
Product Data are recommended. Product Data may also include 25HNA636 HK70EZ004 5.1 33
coil only ratings but a variable speed blower is required to achieve
25HNA648 HK70EZ006 5.1 51
comfort and efficiency.
25HNA660 HK70EZ008 5.1 75
Non--communicating indoor units with properly matched airflow
are available for the 25HNA6/24ANA7 models and are listed in 25HNA924 HK70EZ010 5.1 120
the Product Data. There are no non--communicating indoor units
25HNA936 HK70EZ012 5.1 180
available with the proper airflow for the 25HNA9/24ANA1 units.
25HNA948 HK70EZ014 5.1 270
For this reason, a User Interface (Infinity Control) and Infinity
indoor unit is required with the Copeland UltraTech unit 25HNA960 HK70EZ016 11 5.1
(25HNA9/24ANA1).
25HNA6/24ANA7 Bristol Compressor units may use a standard
2--stage thermostat, or for full utilization of features, the Infinity
zoned or non--zoned control.
Line sets for two stage units are similar to the single stage units.
However, some restrictions may apply to specific combinations in
long line applications. Refer to the Long Line Guideline for further
information.
The Tennessee Valley Authority (TVA) requires that electric strip
heat have a lockout feature. This is achieved through Carrier
thermostats required per above and must be used on all TVA
approved units.
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.

45
Make Airflow Selections for 24ANA7/25HNA6 Defrost
Using Non--Communicating (Non--Infinity) This control offers 5 possible defrost interval times: 30, 60, 90, 120
Thermostats minutes, or AUTO.
On 25HNA6 models, these are selected by dip switches on the unit
Airflow Selection for 58CVA/58MVB Furnaces
control board or by the Infinity Control User Interface. The
The 58CVA/58MVB variable--speed furnaces provide high--and Infinity Control selection overrides the control board dip switch
low--stage blower operation to match the capacities of the settings.
compressor at high and low stages. To select the recommended
On 25HNA9 , the defrost interval times: 30, 60, 90, and 120
airflow and for adjustments to the manual switches labeled SW1--5,
minutes or AUTO are selected by the Infinity Control User
AC, and CF on the control board, refer to the furnace Installation
Interface (the dip switches are not used.)
Instructions. The 58CVA/58MVB utilizes a control center that
allows the installing technician to select the proper airflows. The AUTO defrost adjusts the defrost interval time based on the last
HP switch determines the airflow during high--stage compressor defrost time as follows:
operation. Airflow for high-- and low--stage can be calculated at S When defrost time <3 minutes, the next defrost
either 350 CFM per ton or 400 CFM per ton, based on the interval=120 minutes.
positions of SW1--5. S When defrost time 3--5 minutes, the next defrost
When using communicating (Infinity) control, dipswitch interval=90 minutes.
adjustments are not necessary on furnaces. Airflows are S When defrost time 5--7 minutes, the next defrost
determined by Infinity Control setup. interval=60 minutes.
Airflow Selection for FV4 Fan Coils for S When defrost time >7 minutes, the next defrost interval=30
24ANA7/25HNA6 Using Non--Communicating minutes.
(Non--Infinity) Thermostats The control board accumulates compressor run time. As the
The FV4 provides high-- and low--stage blower operation to match accumulated run time approaches the selected defrost interval time,
the capacities of compressor at high-- and low--stage. To select the control board monitors the coil temperature sensor for a defrost
recommended airflow, refer to FV4 Installation Instructions. The demand. If a defrost demand exists, a defrost cycle will be initiated
FV4 utilizes an Easy Select control board that allows the installing at the end of the selected time interval. A defrost demand exists
technician to select proper airflows. For adjustments to control when the coil temperature is at or below 32_F for 4 minutes during
board, select appropriate HP SIZE and CFM ADJUST setting. This the interval.
fan coil has an adjustable blower off delay factory set at 90 sec for The defrost cycle is terminated when the coil temperature reaches
high-- and low--stage blower operation. 65_F or 10 minutes has passed.
For other combinations of equipment consult Product Data Digest. If the coil temperature does not reach 32_F within the interval, the
GENERAL INFORMATION interval timer will be reset and start over.
Low Ambient Cooling
S Upon initial power up the first defrost interval is defaulted
to 30 minutes. Remaining intervals are at selected times.
When this unit is operating below 55_F outdoor temperature,
provisions must be made for low ambient operation. S Defrost is only allowed to occur below 50_F outdoor
ambient temperature.
Infinity Controlled low ambient cooling:
Defrost Hold
This unit is capable of low ambient cooling without a kit ONLY
when using Infinity control. A low ambient kit is not required, and On 25HNA6 models, in a non--communicating system, if the
the outdoor fan motor does not need to be replaced for Infinity thermostat becomes satisfied (Y1 or Y1 and Y2) before the defrost
controlled low ambient operation. The Infinity Control provides an cycle is terminated, the control will “hold” in defrost mode and
automatic evaporator coil freeze protection algorithm that finish the defrost cycle on the next call for heat.
eliminates the need for an evaporator freeze thermostat. Low On 25HNA6 models, with communicating Infinity Control and all
ambient cooling must be enabled in the User Interface set up. Fan 25HNA9 models, defrost hold is not needed in a communicating
may not begin to cycle until about 40_F OAT. Fan will cycle system because the User Interface will complete the defrost cycle
based on coil and outdoor air temperature. before shutting down the system.
Infinity controlled low ambient mode operates as follows: Forced Defrost
S Fan is OFF when outdoor coil temp is < (outdoor air On 25HNA6 models with non--communicating (non--Infinity)
temperature + 3_F) or outdoor fan has been ON for 30 control, forced defrost can be initiated by manually shorting the
minutes. (Fan is turned off to allow refrigerant system to 2--pin header labeled FORCED DEFROST (see Fig 38) on the
stabilize.) control board for 5 seconds then releasing.
S Fan is ON when outdoor coil temp > (outdoor air On 25HNA6 and 25HNA9 with communicating (Infinity) control,
forced defrost is initiated with the User Interface.
temperature + 25_F) or outdoor coil temp > 80_F or if
outdoor fan has been OFF for 30 minutes. (Fan is turned On all models, during a Forced Defrost:
on to allow refrigerant system to stabilize.) S If coil temperature is at defrost temperature of 32_F, and
S Low pressure switch is ignored for first 3 minutes during outdoor air temperature is below 50_F, a full defrost
low ambient start up. After 3 minutes, if LPS trips, then sequence will occur.
outdoor fan motor is turned off for 10 minutes, with the S If coil temperature or outdoor air temperature does not meet
compressor running. If LPS closes within 10 minutes then the above requirements, an abbreviated 30 second defrost
cooling continues with the outdoor fan cycling per the coil will occur.
temperature routine listed above for the remainder of the
cooling cycle. If the LPS does not close within 10 minutes,
then the normal LPS trip response (shut down cooling
operation and generate LPS trip error) will occur.
For 24ANA1/25HNA9 models, the PWM output for both high and
low stage equals the value for low stage operation below 104_F.

46
Quiet Shift Unit is factory charged for 15ft (4.57 m) of lineset. Adjust charge
Quiet Shift is a field--selectable defrost mode which may eliminate by adding or removing 0.6 oz/ft of 3/8 liquid line above or below
occasional noise that could be heard at the start of the defrost cycle 15ft (4.57 m) respectively.
and restarting of the heating cycle. On 25HNA6 models with For standard refrigerant line lengths (80 ft/24.38 m or less), allow
non--communicating system, this feature must be enabled by system to operate in cooling mode at least 15 minutes. If conditions
selecting the 3rd position of the 3--position dip switch. For are favorable, check system charge by subcooling method. If any
25HNA6 and 25HNA9 models with communicating (Infinity) adjustment is necessary, adjust charge slowly and allow system to
systems, it must be enabled at the User Interface. When activated, operate for 15 minutes to stabilize before declaring a properly
the following sequence of operation will occur. Reversing valve charged system.
will energize and compressor will turn off for 30 seconds, then turn If the indoor temperature is above 80_F (26.67_C), and the
back on to complete defrost. At the end of the defrost cycle, the outdoor temperature is in the favorable range, adjust system charge
reversing valve de--energizes, compressor will turn off for another by weight based on line length and allow the indoor temperature to
30 seconds, and the fan will turn off for 40 seconds, before starting drop to 80_F (26.67_C) before attempting to check system charge
in the heating mode. by subcooling method as described above.
Liquid--Line Solenoid Accessory If the indoor temperature is below 70_F (21.11_C), or the outdoor
In heat pump long--line applications, a liquid--line solenoid is temperature is not in the favorable range, adjust charge for line set
required to control refrigerant migration in the heating mode. The length above or below 15ft (4.57 m) only. Charge level should then
solenoid should be installed near the outdoor unit with the arrow be appropriate for the system to achieve rated capacity. The charge
facing the outdoor unit. This is the direction of flow control. See level could then be checked at another time when the both indoor
application manual for long--line application details. and outdoor temperatures are in a more favorable range.
Accessory Liquid Solenoid with Infinity Communicating NOTE: If line length is beyond 80 ft (24.38 m) or greater than 20
Control: When using the Infinity Control, the liquid--line solenoid ft (6.10 m) vertical separation, See Long Line Guideline for
output is provided at the Y1 connection. Connect the solenoid as special charging requirements.
shown in the wiring label diagram. This is a 24vac output that is Heating Check Chart Procedure
energized whenever the compressor is energized. It closes, in the
compressor off mode, to prevent refrigerant migration into the unit To check system operation during heating cycle, refer to the Heat
through the liquid--line. Pump Charging Instructions label on outdoor unit. This chart
indicates whether a correct relationship exists between system
On 25HNA6 Models with Accessory Liquid Solenoid Using a operating pressure and air temperature entering indoor and outdoor
Non--Communicating Thermostat: The liquid solenoid is units. If pressure and temperature do not match on chart, system
connect to the Y1 and C terminal connections. The liquid solenoid refrigerant charge may not be correct. Do not use chart to adjust
closes, in the compressor off mode, to prevent refrigerant migration refrigerant charge.
into the unit through the liquid--line.
NOTE: In heating mode, check refrigerant charge only when
Check Charge pressures are stable. If in doubt, remove charge and weigh in
All 25HNA6 units must be charged in high stage only. correct refrigerant charge.
Factory charge amount and desired subcooling are shown on unit NOTE: When charging is necessary during heating season, charge
rating plate. Charging method is shown on information plate inside must be weighed in accordance with unit rating plate, ±0.6 oz./ft.
unit. To properly check or adjust charge, conditions must be of 3/8--in. liquid--line above or below 15 ft., respectively.
favorable for subcooling charging. Favorable conditions exist
EXAMPLE:
when the outdoor temperature is between 70_F and 100_F
(21.11_C and 37.78_C), and the indoor temperature is between To calculate additional charge required for a 25--ft. line set:
70_F and 80_F (21.11_C and 26.67_C). Follow the procedure 25 ft. -- 15 ft. = 10 ft. X 0.6 oz./ft. = 6 oz. of additional charge.
below:

47
 Table 16—Required Liquid--Line Temperature (°F)

LIQUID PRESSURE REQUIRED SUBCOOLING TEMPERATURE (°F)

AT SERVICE VALVE
(PSIG) 8 10 12 14 16 18
251 76 74 72 70 68 66
259 78 76 74 72 70 68
266 80 78 76 74 72 70
274 82 80 78 76 74 72
283 84 82 80 78 76 74
291 86 84 82 80 78 76
299 88 86 84 82 80 78
308 90 88 86 84 82 80
317 92 90 88 86 84 82
326 94 92 90 88 86 84
335 96 94 92 90 88 86
345 98 96 94 92 90 88
354 100 98 96 94 92 90
364 102 100 98 96 94 92
374 104 102 100 98 96 94
384 106 104 102 100 98 96
395 108 106 104 102 100 98
406 110 108 106 104 102 100
416 112 110 108 106 104 102
427 114 112 110 108 106 104
439 116 114 112 110 108 106
450 118 116 114 112 110 108
462 120 118 116 114 112 110
474 122 120 118 116 114 112
486 124 122 120 118 116 114
499 126 124 122 120 118 116
511 128 126 124 122 120 118

48
System Functions and Sequence of Operation Utility Interface With Infinity Control
The outdoor unit control system has special functions. The The utility curtailment relay should be wired between R and Y2
following is an overview of the two--stage control functions: connections on the control board for Infinity Communicating
Cooling and Heating Operation Systems only (see Fig. 41.) This input allows a power utility device
to interrupt compressor operation during peak load periods. When
The 25HNA6/24ANA7 model utilizes either a standard indoor the utility sends a signal to shut the system down, the User
thermostat or Infinity Communication User Interface. The Interface will display, “Curtailment Active”.
25HNA9/24ANA1 models utilize an Infinity communicating User
One Minute Stage Change Time Delay on 25HNA6/24ANA7
Interface only. With a call for first stage cooling, the outdoor fan,
reversing valve, and low stage compressor are energized. If Models
low--stage cannot satisfy cooling demand, high--stage cooling is When compressor changes stages from high to low or low to high,
energized by the second stage of indoor thermostat or User there is a 1--minute time delay before compressor restarts. The
Interface. After second stage is satisfied, the unit returns to outdoor fan motor remains running.
low--stage operation until first stage is satisfied or until second Compressor Operation on 25HNA6/24ANA7 Models
stage is required again. When both first stage and second stage These units contain a Bristol 2--stage reciprocating compressor.
cooling are satisfied, the compressor will shut off. The reversing When the compressor operates in high stage operation, the
valve will remain energized until the control board power is compressor motor rotates clockwise. Both the lower and upper
removed or a call for heating in initiated. With a call for heating, pistons are eccentric with the rotating crankshaft and both
the outdoor fan and compressor are energized. The compressor will compress refrigerant.
operate in high or low stage operation, as needed to meet the
When the compressor operates in low stage operation, the
heating demand. When the heating demand is satisfied, the
compressor motor reverses direction (rotates counterclockwise).
compressor and fan will shut off. The reversing valve is
The lower piston becomes idle and the upper piston compresses
de--energized in the heating mode.
refrigerant. The start and run windings are reversed.
NOTE: When two--stage unit is operating at low--stage, system
Crankcase Heater Operation
vapor (suction) pressure will be higher than a standard single--stage
system or high--stage operation. The two--stage reciprocating compressor does not have a
replaceable CCH available. It is recommended to disconnect,
NOTE: Outdoor fan motor will continue to operate for one minute
electronically, the faulty CCH and add a belly band style CCH
after compressor shuts off, when outdoor ambient is greater than or should a CCH failure be determined.
equal to 100°F. This reduces pressure differential for easier starting
Compressor Operation on 25HNA9/24ANA1 Models:
on next cycle.
The basic scroll design has been modified with the addition of an
NOTE: On 25HNA6/24ANA7 models, if unit has not operated
internal unloading mechanism that opens a bypass port in the first
within the past 12 hours, or following a unit power--up, upon the
compression pocket, effectively reducing the displacement of the
next thermostat high-- or low--stage demand, unit operates for a scroll. The opening and closing of the bypass port is controlled by
minimum of 5 minutes in high--stage. an internal electrically operated solenoid.
On 25HNA6/24ANA7 models with non--communicating The modulated scroll uses a single step of unloading to go from
(non--Infinity) systems, with first stage of cooling, Y1 and O are full capacity to approximately 67% capacity. A single speed, high
powered on; and with second stage of cooling, Y1, Y2, and O are efficiency motor continues to run while the scroll modulates
on. For these systems, with first stage of heating Y1 is on and for between the two capacity steps. Modulation is achieved by venting
second stage of heating, Y1 and Y2 are on. When the reversing a portion of the gas in the first suction pocket back to the low side
valve is energized, O is powered on. of the compressor, thereby reducing the effective displacement of
Communication and Status Function Lights For Infinity the compressor. Full capacity is achieved by blocking these vents,
Control only, Green communications (COMM) Light thus increasing the displacement to 100%. A DC solenoid in the
A green LED (COMM light) on the outdoor board indicates compressor controlled by a rectified 24 volt AC signal in the
successful communication with the other system products. The external solenoid plug moves the slider ring that covers and
green LED will remain OFF until communication is established. uncovers these vents. The vent covers are arranged in such a
Once a valid command is received, the green LED will turn ON manner that the compressor operates at approximately 67%
continuously. If no communication is received within 2 minutes, capacity when the solenoid is not energized and 100% capacity
the LED will be turned OFF until the next valid communication. when the solenoid is energized.
Amber Status Light The loading and unloading of the two step scroll is done “on the
fly” without shutting off the motor between steps.
An amber colored STATUS light is used to display the operation
mode and fault codes as specified in the troubleshooting section. NOTE: 67% compressor capacity translates to approximately 80%
See Table 19 for codes and definitions. cooling or heating capacity at the indoor coil. The compressor will
NOTE: Only one code will be displayed on the outdoor unit always start unloaded and stay unloaded for five seconds even
control board (the most recent, with the highest priority). when the thermostat is calling for high stage.

49
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 17. 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.
Located above the compressor is a single--speed fan motor and fan. Table 17—Outdoor Fan Motor PWM Above 55_F/12.7_C
The 24ANA1/25HNA9 air conditioner and heat pump models use Outdoor Temp (DC volts, Tolerance +/-- 2%)
the ECM variable speed fan motor. Low & High
Low Stage
The outdoor Integral Control Motor (ECM), is a variable--speed High Stage Stage
Model (OAT≤104_F)
motor which operates from 450 to 850 rpm. The motor is a dc DC Volts
(OAT≤104_F) (OAT>104_F)
permanent magnet--type motor with the electronic controls DC Volts
integrated into its rear cover. The control package includes a small 25HNA924 4.0 4.8 10.0
diode bridge, capacitors, and power switching devices. It converts 25HNA936 4.5 6.5 10.0
ac to dc power and switches the dc power to the motor windings on 25HNA948 6.0 8.1 10.0
and off at various rates to control the motor speed. The speed at 25HNA960 7.8 9.6 10.0
which the motor windings are thus commutated is determined by a 24ANA124 5.0 7.6 10.0
pulse width modulated (PWM) signal which is received from the
24ANA136 4.5 6.5 10.0
control board on the motor control lines.
24ANA148 6.0 8.1 10.0
The PWM signal is created by turning a DC signal on and off once
24ANA160 7.8 9.6 10.0
within a given period of time. The signal on time relative to the NOTE: For models in low---ambient cooling, the PWM output for both
signal total period defines the percent of the PWM. For example, if high --- and low---stage equals the value for low---stage operation
the period is 5 sec and the control power is turned on for 1 sec then below 104_F.
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
signal. If the on time is increased to 4 sec of the 5 sec period, the
PWM is called an 80 percent duty cycle. The ECM reads the PWM
signal and increases the motor speed linearly from minimum speed
to maximum speed with the percent duty cycle value of the
supplied PWM signal.

50
ECM Fan Motor Troubleshooting Muffler, Accumulator, Reversing Valve (RVS)
If the outdoor fan motor fails to start and run: The Puronr two--stage air conditioners and heat pumps have a
S Check the high--voltage supply. The unit need not be compressor discharge line muffler, to dampen sound pressure
running to check high voltage, but the power must be on. pulsations.
S If the 230vac is present, use Table 17 to check for proper The Puronr two--stage heat pumps have a specifically designed
control voltage output to the fan motor from the control reversing valve, for Puronr application and an accumulator for
board. The control board sends DC voltage signals to the storing excess liquid refrigerant during the heating mode to prevent
motor through the terminals labeled PWM1 and PWM2 damaging flood--back.
Set a voltmeter on a DC voltage scale and check across Thermistors
these terminals. Outdoor Ambient Thermistor
S First check voltage with the motor disconnected. If no The Puronr two--speed air conditioner and heat pump units have
control voltage is present, check control--board an outdoor ambient air thermistor. The control board must know
connections. If connections are good, replace the control the outdoor air temperature so it can activate various functions.
board. These functions include:
S If voltage is present, reconnect the motor and check S Activating the compressor crankcase heater when ever
again. Shut down the unit to reconnect the motor and the outdoor unit is in the off cycle.
restart the unit to complete this troubleshooting The fan motor speed changes for both air conditioner
S
procedure. If control voltage is no longer present or
and heat pump on the ECM equipped units.
motor fails to respond, check motor connections.
Outdoor Coil Thermistor(OCT)
S If connections are good, replace the motor.
The coil or defrost thermistor is the same thermistor used to
Time Delays monitor outdoor air temperature. The control board must know the
The unit time delays include: coil temperature so it can activate various functions. These
functions include:
S Five minute time delay to start cooling or heating operation
when there is a call from the thermostat or user interface. To S Frost sensing on heat pumps
bypass this feature, momentarily short and release Forced S Coil--vs--Ambient temperature relationship
Defrost pins.
Low ambient cooling operation
S
S Five minute compressor re--cycle delay on return from a
Thermistor Curve
brown--out condition.
The resistance vs. temperature chart enables the service technicians
S Two minute time delay to return to standby operation from to check thermistor resistance, regardless of the temperature.
last valid communication (with Infinity only).
For example, at a 60_F temperature, thermistor resistance should
S One minute time delay of outdoor fan at termination of be around 16,000 Ohms. (See Fig. 34.)
cooling mode when outdoor ambient is greater than or We will talk about the thermistor in more detail when we review
equal to 100_F. the control board fault codes.
S Fifteen second delay at termination of defrost before the
auxiliary heat (W1) is de--energized. THERMISTOR CURVE
S Twenty second delay at termination of defrost before the 90
outdoor fan is energized. 80
S Thirty second compressor delay when quiet shift enabled.
RESISTANCE (KOHMS)

70
S On 25HNA6 models there is a 1 minute time delay between 60
staging from low to high and from high to low capacity. On
50
25HNA9 models there is no delay; the compressor will
change from low to high and from high to low capacity “on 40
the fly” to meet the demand. 30
Pressure Switches 20
The Puronr two--stage air conditioner contains two pressure 10
switches to prevent system operation if the pressures get
0
excessively high or low. The air conditioner low pressure switch in 0 20 40 60 80 100 120
the suction line opens at 50 PSI and closes at 95 PSI. The high (-17.77) (-6.67) (4.44) (15.56) (26.67) (37.78) (48.89)
pressure switch opens at 670 PSI and closes at 420 PSI. Both TEMPERATURE °F (°C)
pressure switch settings are considerably higher than on
comparably sized R--22 units. The high and low pressure switches A08054
can be identified by their pink stripe on the switch’s electrical Fig. 34 – Resistance Values Versus Temperature
wires.
The Puronr two--stage heat pump contains a loss of charge switch
in the liquid line which opens at 23 PSI and closes at 55 PSI. See
troubleshooting section for sequence when a pressure switch trip
occurs.

51
Control Box Start Circuit -- 24ANA7 & 25HNA6
Contactor And Capacitor These models use the same Bristol TS reciprocating compressor
that was used in previous 2--stage Puron units. A start circuit is
Removal of the information plate exposes the control components.
needed so that the reciprocating compressor will start against
Both air conditioner and heat pump control boxes will appear to be
elevated head pressure. The start circuit these units use is different
nearly identical. There are two contactors, two capacitors, a control
from previous units. The start relay is a normally open type, and is
board and a compressor start assist. The contactors are identical to
controlled by the circuit board instead of directly sensing the
those used in the standard single speed units. One controls low
compressor voltage.
capacity operation and the second controls high speed. The
capacitors also are similar to those used in standard single speed Start Circuit Sequence of Operation -- 24ANA7 & 25HNA6
units. You have a fan capacitor for the outdoor fan motor, and a run On a call for high-- or low--stage compressor operation, the start
capacitor for the compressor motor. The control board, start relay is closed by the control board through the Vs, Vr, and L2
capacitor, and start relay control the starting of the compressor. terminals. This puts the start capacitor in the circuit. Compressor
Always replace these devices with the Factory Approved voltage is sensed on the VR and VS terminals throughout the
Components. process. As the compressor comes up to speed, the control board
Incoming Power senses the change in voltage across VR and VS, and opens the start
relay at the appropriate voltage. The control is programmed with
Incoming power is attached to the two power wire stripped leads. the parameters for opening the start circuit. The voltage will be
A ground lug is also provided. Outdoor unit should always be different for high-- and low--stage, and for different unit sizes.
grounded through the ground lug to the unit disconnect and from
Since the same control board is used in all 2--stage units, the model
the disconnect to the electrical fuse box. Failure to do so can cause
plug determines the start circuit voltage.
serious injury or death.
Troubleshooting 24ANA7 & 25HNA6 Start Circuit:
If starting problems are encountered, the control board will flash
fault codes to help indicate where the problem was encountered.
See Table 19 for appropriate actions by active fault code.
S First check that the model plug is correct for the unit
model and size, and that it is installed properly

Fig. 35 – Performance and Infinity Series Control Box Identification

52
 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 Pressure Switch Protection

Troubleshooting (HK38EA003, 008, 010) circuit boards. 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 1. De--energize the appropriate compressor contactor.
Plug section) There were two part number changes to this board 2. Keep the outdoor fan operating for 15 minutes.
early in 2006 due to expansion of the Infinity split system product 3. Display the appropriate fault code (see Table 19).
line, and expansion of the Infinity Small Packaged Product (SPP)
line. This circuit board is used in both Infinity split system and 4. After a 15 minute delay, if there is a call for cooling or
Infinity SPP systems. heating and LPS or HPS is reset, the appropriate
compressor contactor is energized.
Replacement boards may have a different part number from the
original board. A newer board will always be backward compatible 5. If LPS or HPS has not closed after a 15 minute delay, the
to previous units if it is superceded at RCD. Old boards are not outdoor fan is turned off. If the open switch closes anytime
always forward compatible due to new functions, or software after the 15 minute delay, then resume operation with a call
changes made to resolve field issues. for cooling or heating.
Systems Communication Failure 6. If LPS or HPS trips 3 consecutive cycles, the unit operation
is locked out for 4 hours.
If communication with the Infinity control is lost with the User
7. In the event of a high--pressure switch trip or high--pressure
Interface, the control will flash the appropriate fault code. (See
Table 19.) Check the wiring to the UI and the indoor and outdoor lockout, check the refrigerant charge, outdoor fan operation,
and outdoor coil (in cooling) for airflow restrictions, or
units.
indoor airflow in heating.
Model Plug
8. In the event of a low--pressure switch trip or low--pressure
Each control board contains a model plug. The correct model plug lockout, check the refrigerant charge and indoor airflow
must be installed for or the system to operate properly. (See Table (cooling) and outdoor fan operation and outdoor coil in
15.) heating.
The model plug is used to identify the type and size of unit to the Control Fault
control. On 25HNA6 models, the model plug is also used to
determine the start sequence timing for each individual model. If the outdoor unit control board has failed, the control will flash
the appropriate fault code (see Table 19). The control board should
On new units, the model and serial numbers are input into the be replaced.
board’s memory at the factory. If a model plug is lost or missing at
initial installation, the unit will operate according to the Brown--Out Protection
information input at the factory and the appropriate error code will If the line voltage is less than 187v for at least 4 seconds, the
flash temporarily.. An RCD replacement board contains no model appropriate compressor contactor and fan relay are de--energized.
and serial information. If the factory control board fails, the model Compressor and fan operation are not allowed until voltage is a
plug must be transferred from the original board to the replacement minimum of 190v. The control will flash the appropriate fault code
board for the unit to operate. (see Table 19).
NOTE: The model plug takes priority over factory model 230V Line (Power Disconnect) Detection
information input at the factory. If the model plug is removed after If there is no 230v at the compressor contactor(s) when the indoor
initial power up, the unit will operate according to the last valid unit is powered and cooling or heating demand exists, the
model plug installed, and flash the appropriate fault code appropriate fault code is displayed. Verify the disconnect is closed
temporarily. and 230v wiring is connected to the unit.

53
Compressor Voltage Sensing If the specified start voltage is not achieved for 3 consecutive low
The control board input terminals labeled VS, VR and L2 on stage starts, low stage operation is locked out for 30 minutes. If the
25HNA6/24ANA7 models and VS and L2 on 25HNA9/24ANA1 specified start voltage is not achieved for 3 consecutive high stage
models (see Fig. 36) are used to detect compressor voltage status starts, high stage operation is locked out for 30 minutes. The
and alert the user of potential problems. The control continuously control will flash the appropriate fault code.
monitors the high voltage on the run capacitor of the compressor Troubleshooting 25HNA6 units for proper switching between
motor. Voltage should be present any time the compressor low & high stages
contactor is energized and voltage should not be present when the Check the suction and liquid pressures at the service valves.
contactor is de--energized. Suction pressure should be reduced by 5--10% when switching
Contactor Shorted Detection from low to high capacity. There should be a 10--20% increase in
If there is compressor voltage sensed when there is no demand for liquid pressure when switching from low to high capacity.
compressor operation, the contactor may be stuck closed or there Compressor current should increase 100--250% when switching
may be a wiring error. The control will flash the appropriate fault from low to high stage.
code. Troubleshooting 25HNA9 units for proper switching between
25HNA6 Models -- Compressor Thermal Cutout low & high stages
The control senses the compressor voltage at VR and VS. When Check the suction pressures at the service valves. Suction pressure
starting or running, a phase difference of the voltages on the inputs should be reduced by 3--10% when switching from low to high
will indicate the thermal protector is closed. If the phase difference capacity.
is 5_ or less for 10 seconds, the internal protector is open. The NOTE: The liquid pressures are very similar between low and
control de--energizes the appropriate compressor contactor for 15 high stage operation, so liquid pressure should not be used for
minutes, but continues to operate the outdoor fan. The control troubleshooting.
Status LED will flash the appropriate code shown in Table 19. Compressor current should increase 20--45% when switching from
After 15 minutes, with a call for low or high stage cooling or low to high stage. The compressor solenoid when energized in
heating, the appropriate compressor contactor is energized. If the high stage, should measure 24vac.
thermal protector has not re--set, the outdoor fan is turned off. If
the call for cooling or heating continues, the control will energize When the compressor is operating in low stage the 24v DC
the compressor contactor every 15 minutes. If the thermal compressor solenoid coil is de--energized. When the compressor is
protector closes, (at the next 15 minute interval check) the unit will operating in high stage, the 24v DC solenoid coil is energized. The
resume operation. solenoid plug harness that is connected to the compressor HAS an
internal rectifier that converts the 24v DC signal to 24v AC. DO
If the thermal cutout trips for three consecutive cycles, then unit NOT INSTALL A PLUG WITHOUT AN INTERNAL
operation is locked out for 4 hours and the appropriate fault code is RECTIFIER.
displayed.
Unloader Test Procedure
25HNA9 Compressor Thermal Cutout
The unloader is the compressor internal mechanism, controlled by
If the control senses the compressor voltage after start--up and is the DC solenoid, that modulates between high and low stage. If it
then absent for 10 consecutive seconds while cooling or heating is suspected that the unloader is not working, the following
demand exists, the thermal protector is open. The control methods may be used to verify operation.
de--energizes the compressor contactor for 15 minutes, but
continues to operate the outdoor fan. The control Status LED will 1. Operate the system and measure compressor amperage.
flash the appropriate code shown in Table 19. After 15 minutes, Cycle the unloader on and off at 30 second plus intervals at
with a call for low or high stage cooling or heating, the compressor the UI (from low to high stage and back to low stage). Wait
contactor is energized. If the thermal protector has not re--set, the 5 seconds after staging to high before taking a reading. The
outdoor fan is turned off. If the call for cooling or heating compressor amperage should go up or down at least 20
continues, the control will energize the compressor contactor every percent.
15 minutes. If the thermal protector closes, (at the next 15 minute 2. If the expected result is not achieved, remove the solenoid
interval check) the unit will resume operation. plug from the compressor and with the unit running and the
If the thermal cutout trips for three consecutive cycles, then unit UI calling for high stage, test the voltage output at the plug
operation is locked out for 4 hours and the appropriate fault code is with a DC voltmeter. The reading should be 4 to 18 volts.
displayed. 3. If the correct DC voltage is at the control circuit molded
Low or High Contactor Open (25HNA6 models) / No 230V at plug, measure the compressor unloader coil resistance. The
Compressor Contractor (25HNA9 models) resistance should be 32 to 60 ohms depending on
compressor temperature. If the coil resistance is infinity,
If the compressor voltage is not sensed when the compressor much lower than 32 ohms, or is grounded, the compressor
should be starting, the appropriate contactor may be stuck open or must be replaced.
there is a wiring error. The control will flash the appropriate fault
code. Check the contactor and control box wiring. Temperature Thermistors
25HNA6 Models Only -- Compressor Start Detection on Thermistors are electronic devices which sense temperature. As the
Models with Bristol Compressors Only temperature increases, the resistance decreases. Thermistors are
used to sense outdoor air (OAT) and coil temperature (OCT).
In low stage, if the specified start voltage at VR terminal is not Refer to Fig. 34 for resistance values versus temperature.
achieved, the start relay is de--energized after 1 second and the
If the outdoor air or coil thermistor should fail, the control will
control will flash the appropriate fault code.
flash the appropriate fault code. (See Table 19.)
In high stage, if the specified start voltage at VS terminal is not
IMPORTANT: The outdoor air thermistor and coil thermistor
achieved, the start relay is de--energized after 1 second and the
control will flash the appropriate fault code. should be factory mounted in the final locations. Check to
ensure thermistors are mounted properly per Fig. 37 and Fig.
38.

54
Thermistor Sensor Comparison Failed Thermistor Default Operation
The control continuously monitors and compares the outdoor air Factory defaults have been provided in the event of failure of
temperature sensor and outdoor coil temperature sensor to ensure outdoor air thermistor (OAT) and/or outdoor coil thermistor
proper operating conditions. The comparison is: (OCT).
S In cooling if the outdoor air sensor indicates ≥ 10_F If the OAT sensor should fail, low ambient cooling will not be
warmer than the coil sensor (or) the outdoor air sensor allowed and the one--minute outdoor fan off delay will not occur.
indicates ≥ 20_F cooler than the coil sensor, the sensors are Defrost will be initiated based on coil temperature and time.
out of range. If the OCT sensor should fail, low ambient cooling will not be
S In heating if the outdoor air sensor indicates ≥ 35_F warmer allowed. Defrost will occur at each time interval during heating
than the coil sensor (or) the outdoor air sensor indicates ≥ operation, but will terminate after 5 minutes.
10_F cooler than the coil sensor, the sensors are out of If there is a thermistor out of range error, defrost will occur at each
range. time interval during heating operation, but will terminate after 5
If the sensors are out of range, the control will flash the appropriate minutes.
fault code as shown in Table 19. Count the number of short and long flashes to determine the
The thermistor comparison is not performed during low ambient appropriate flash code. Table 19 gives possible causes and actions
cooling or defrost operation. 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 18—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

Winding 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

Status Codes
Table 19 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 19 shows this to be low pressure switch open.

55
 Table 19—TROUBLESHOOTING
AMBER
LED
OPERATION FAULT POSSIBLE CAUSE AND ACTION
FLASH
CODE
On solid,
Standby – no call for unit operation None Normal operation
no flash
Standard Thermo-
Rapid, Unit being controlled by standard thermostat inputs instead of Infinity Con-
Emergency Mode --- Model stat Control
continuous trol. Only high stage operation is available. This operating mode should be
25HNA9/24ANA1 only (25HNA9/24ANA1
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 Commu- Communication with User Interface lost. Check wiring to UI, indoor and
16
nications 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 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
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
47 heating demand exists. Verify the disconnect is closed and 230v wiring is
and L2 on circuit
connected to the unit.
board
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
72* exists. Possible causes are internal compressor overload trip or start relay
Thermal Cutout
and capacitor held in circuit too long (if installed).
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
Thermal Lockout stage locked out for 4 hours or until 24v power recycled.
Low---Pressure Low pressure switch trip has occurred during 3 consecutive cycles. Unit
83
Lockout 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
Compressor voltage not sensed when compressor should be starting. Low
Open 85
stage contactor may be stuck open or there is a wiring error.
(25HNA6 Only)
High Contactor
Compressor voltage not sensed when compressor should be starting. High
Open 87
stage contactor may be stuck open or there is a wiring error.
(25HNA6 Only)
*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.

56
 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 25HNA6 Two-- Stage Heat Pump (non-- communicating) Speed Furnace and 25HNA6 Two-- Stage Heat Pump (non-- communi-
(applies to 25HNA6 Models Only) cating) (applies to 25HNA6 Models Only)

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 25HNA6 OR 25HNA9 Communicating Two-- Stage HP

57
CARE AND MAINTENANCE
To assure high performance and minimize possible equipment Cleaning Coil
malfunction, it is essential that maintenance be performed
1. Remove top cover. (See Remove Top Cover in Cabinet
periodically on this equipment. The frequency with which
section of this manual.)
maintenance is performed is dependent on such factors as hours of
operation, geographic location, and local environmental
conditions. ! CAUTION
! WARNING UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
ELECTRICAL SHOCK HAZARD damage or improper operation.
Failure to follow this warning could result in personal Coil fin damage can result in higher operating costs or
injury or death. compressor damage. Do not use flame, high--pressure water,
Disconnect all electrical power to unit before performing steam, volatile or corrosive cleaners on fins or tubing.
any maintenance or service on outdoor unit. Remember to
disconnect power supply to air handler as this unit supplies 2. Clean coil using vacuum cleaner and its crevice tool. Move
low--voltage power to the outdoor unit. crevice tool vertically, close to area being cleaned, making
sure tool touches only dirt on fins and not fins. to prevent
The minimum maintenance that should be performed on this fin damage, do not scrub fins with tool or move tool
equipment is as follows: horizontally against fins.
1. Check outdoor coil for cleanliness each heating and cooling 3. If oil deposits are present, spray coil with ordinary
season and clean as necessary. household detergent. Wait 10 minutes, and proceed to next
2. Check fan motor and blade for cleanliness each month step.
during cooling season and clean as necessary. 4. Using garden hose, spray coil vertically downward with
3. Check electrical connections for tightness and controls for constant stream of water at moderate pressure. Keep nozzle
proper operation each cooling season and service as at a 15-- to 20_ angle, about 3 in. from coil face and 18 in.
necessary. from tube. Spray so debris is washed out of coil and
basepan.

! CAUTION 5. Reinstall top cover and position blade.

6. Reconnect electrical power and check for proper operation.
UNIT DAMAGE HAZARD Cleaning Outdoor Fan Motor and Blade
Failure to follow this caution may result in equipment 1. Remove fan motor and blade. Be careful not to bend or dent
damage or improper operation. fan blade.
Because of possible damage to the equipment or personal 2. Clean motor and blade with soft brush or cloth. Be careful
injury, maintenance should be performed by qualified not to disturb balance weights on fan blade.
personnel only. 3. Check fan blade setscrew for tightness.
4. Reinstall fan motor and blade to top cover and check for
Desert and Seacoast Locations alignment.
Special consideration must be given to installation and 5. Reinstall top cover and position blade.
maintenance of condensing units installed in coastal or desert 6. Reconnect electrical power and check for proper operation.
locations. This is because salt and alkali content of sand adheres to Electrical Controls and Wiring
aluminum fins of coil and can cause premature coil failure due to
corrosion. 1. Disconnect power to both outdoor and indoor units.
Preventive measures can be taken during installations, such as: 2. Check all electrical connections for tightness. Tighten all
screws on electrical connections. If any connections appear
1. Locate unit on side of structure opposite prevailing winds.
to be burned or smoky, disassemble the connection, clean
2. Elevate unit to height where drifting sand cannot pile up all parts and stripped wires, and reassemble. Use a new
against coil. Mounting feet, 4 in. high, are available as connector if old one is burned or corroded, and crimp
accessories and can be used to elevate unit. tightly.
3. Addition of coastal filter (See Product Data Digest for 3. Reconnect electrical power to indoor and outdoor units and
accessory listing). observe unit through 1 complete operating cycle.
Maintenance in desert and seacoast locations: 4. If there are any discrepancies in operating cycle,
1. Frequent inspection of coil and basepan especially after troubleshoot to find cause and correct.
storms and/or high winds. Refrigerant Circuit
2. Clean coil by flushing out sand from between coil fins and 1. Check refrigerant charge using the superheat method, and if
out of basepan as frequently as inspection determines low on charge, check unit for leaks using an electronic leak
necessary. detector.
3. In off season, cover with covering that allows air to circulate 2. If any leaks are found, remove and reclaim or isolate charge
through but prevents sand from sifting in (such as canvas
(pumpdown) if applicable. Make necessary repairs.
material). Do not use plastic as plastic will hold moisture
possibly causing corrosion. 3. Evacuate, recharge, and observe unit through 1 complete
operating cycle.

58
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.

59
 Table 20—Pressure vs. Temperature Chart -- Puronr Refrigerant (R--410a)
PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F
12 –37.7 114 37.8 216 74.3 318 100.2 420 120.7 522 137.6
14 –34.7 116 38.7 218 74.9 320 100.7 422 121.0 524 137.9
16 –32.0 118 39.5 220 75.5 322 101.1 424 121.4 526 138.3
18 –29.4 120 40.5 222 76.1 324 101.6 426 121.7 528 138.6
20 –26.9 122 41.3 224 76.7 326 102.0 428 122.1 530 138.9
22 –24.5 124 42.2 226 77.2 328 102.4 430 122.5 532 139.2
24 –22.2 126 43.0 228 77.8 330 102.9 432 122.8 534 139.5
26 –20.0 128 43.8 230 78.4 332 103.3 434 123.2 536 139.8
28 –17.9 130 44.7 232 78.9 334 103.7 436 123.5 538 140.1
30 –15.8 132 45.5 234 79.5 336 104.2 438 123.9 540 140.4
32 –13.8 134 46.3 236 80.0 338 104.6 440 124.2 544 141.0
34 –11.9 136 47.1 238 80.6 340 105.1 442 124.6 548 141.6
36 –10.1 138 47.9 240 81.1 342 105.4 444 124.9 552 142.1
38 –8.3 140 48.7 242 81.6 344 105.8 446 125.3 556 142.7
40 –6.5 142 49.5 244 82.2 346 106.3 448 125.6 560 143.3
42 –4.5 144 50.3 246 82.7 348 106.6 450 126.0 564 143.9
44 –3.2 146 51.1 248 83.3 350 107.1 452 126.3 568 144.5
46 –1.6 148 51.8 250 83.8 352 107.5 454 126.6 572 145.0
48 0.0 150 52.5 252 84.3 354 107.9 456 127.0 576 145.6
50 1.5 152 53.3 254 84.8 356 108.3 458 127.3 580 146.2
52 3.0 154 54.0 256 85.4 358 108.8 460 127.7 584 146.7
54 4.5 156 54.8 258 85.9 360 109.2 462 128.0 588 147.3
56 5.9 158 55.5 260 86.4 362 109.6 464 128.3 592 147.9
58 7.3 160 56.2 262 86.9 364 110..0 466 128.7 596 148.4
60 8.6 162 57.0 264 87.4 366 110.4 468 129.0 600 149.0
62 10.0 164 57.7 266 87.9 368 110.8 470 129.3 604 149.5
64 11.3 166 58.4 268 88.4 370 111.2 472 129.7 608 150.1
66 12.6 168 59.0 270 88.9 372 111.6 474 130.0 612 150.6
68 13.8 170 59.8 272 89.4 374 112.0 476 130.3 616 151.2
70 15.1 172 60.5 274 89.9 376 112.4 478 130.7 620 151.7
72 16.3 174 61.1 276 90.4 378 112.6 480 131.0 624 152.3
74 17.5 176 61.8 278 90.9 380 113.1 482 131.3 628 152.8
76 18.7 178 62.5 280 91.4 382 113.5 484 131.6 632 153.4
78 19.8 180 63.1 282 91.9 384 113.9 486 132.0 636 153.9
80 21.0 182 63.8 284 92.4 386 114.3 488 132.3 640 154.5
82 22.1 184 64.5 286 92.8 388 114.7 490 132.6 644 155.0
84 23.2 186 65.1 288 93.3 390 115.0 492 132.9 648 155.5
86 24.3 188 65.8 290 93.8 392 115.5 494 133.3 652 156.1
88 25.4 190 66.4 292 94.3 394 115.8 496 133.6 656 156.6
90 26.4 192 67.0 294 94.8 396 116.2 498 133.9 660 157.1
92 27.4 194 67.7 296 95.2 398 116.6 500 134.0 664 157.7
94 28.5 196 68.3 298 95.7 400 117.0 502 134.5 668 158.2
96 29.5 198 68.9 300 96.2 402 117.3 504 134.8 672 158.7
98 30.5 200 69.5 302 96.6 404 117.7 506 135.2 676 159.2
100 31.2 202 70.1 304 97.1 406 118.1 508 135.5 680 159.8
102 32.2 204 70.7 306 97.5 408 118.5 510 135.8 684 160.3
104 33.2 206 71.4 308 98.0 410 118.8 512 136.1 688 160.8
106 34.1 208 72.0 310 98.4 412 119.2 514 136.4 692 161.3
108 35.1 210 72.6 312 98.9 414 119.6 516 136.7 696 161.8
110 35.5 212 73.2 314 99.3 416 119.9 518 137.0
112 36.9 214 73.8 316 99.7 418 120.3 520 137.3

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 Table 21—Required Liquid--Line Temperature

LIQUID PRESSURE REQUIRED SUBCOOLING TEMPERATURE (°F)

AT SERVICE VALVE
(PSIG) 8 10 12 14 16 18
251 76 74 72 70 68 66
259 78 76 74 72 70 68
266 80 78 76 74 72 70
274 82 80 78 76 74 72
283 84 82 80 78 76 74
291 86 84 82 80 78 76
299 88 86 84 82 80 78
308 90 88 86 84 82 80
317 92 90 88 86 84 82
326 94 92 90 88 86 84
335 96 94 92 90 88 86
345 98 96 94 92 90 88
354 100 98 96 94 92 90
364 102 100 98 96 94 92
374 104 102 100 98 96 94
384 106 104 102 100 98 96
395 108 106 104 102 100 98
406 110 108 106 104 102 100
416 112 110 108 106 104 102
427 114 112 110 108 106 104
439 116 114 112 110 108 106
450 118 116 114 112 110 108
462 120 118 116 114 112 110
474 122 120 118 116 114 112
486 124 122 120 118 116 114
499 126 124 122 120 118 116
511 128 126 124 122 120 118

61
 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. 42 – Air Conditioner Troubleshooting Chart

62
 HEAT PUMP
TROUBLESHOOTING HEATING CYCLE

NO HEATING OR
INSUFFICIENT
HEATING

COMPRESSOR COMPRESSOR
COMPRESSOR RUNS BUT RUNS
WILL NOT RUN CYCLES ON INSUFFICIENT
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. 43 – Heat Pump Troubleshooting -- Heating Cycle

63
 HEAT PUMP
TROUBLESHOOTING COOLING CYCLE

NO COOLING OR
INSUFFICIENT
COOLING

COMPRESSOR COMPRESSOR
COMPRESSOR RUNS BUT RUNS BUT
WILL NOT RUN CYCLES ON INSUFFICIENT
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. 44 – Heat Pump Troubleshooting -- Cooling Cycle

64
 INDEX OF TABLES
DESCRIPTION TABLE #
Required Field--Installed Accessories for Air Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Required Field--Installed Accessories for Heat Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tech Assistt Diagnostics At--a--Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Defrost Control Speed--Up Timing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fitting Losses in Equivalent Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Puron System Suction Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
R--22 System Suction Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Puron Refrigerant Pressure Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
R--22 Refrigerant Pressure Temperature Relationship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Puron Subcooling Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Puron Superheat Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
R--22 Subcooling Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
R--22 Superheat Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Model Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Required Liquid--Line Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Outdoor Fan Motor PWM Above 55_F/12.7_C Outdoor Temp (DC volts, Tolerance +/-- 2%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Two--Stage Compressor Resistnaces (Winding resistance at 70_F ± 20_) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Puron Pressure vs. Temperature Chart (two--stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Required Liquid--Line Temperature (two--stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

65
Copyright 2008 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 04/08 Catalog No.24---25---2SM
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces:24--- 25--- 1SM

66