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1. FROM COMPRESSOR DISCHARGE LINE ELECTRONIC THERMOMETER A88341 Fig 23 Reversing Valve Heating Mode Solenoid De Energized Liquid Line Filter Drier Filter driers are specifically designed for R 22 or Puron refrigerant Only operate with the appropriate drier using factory authorized components It is recommended that the liquid line drier be installed at the indoor unit Placing the drier near the TXV allows additional protection to the TXV as the liquid line drier also acts as a strainer CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation To avoid performance loss and compressor failure installation of filter drier in liquid line is required CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation To avoid filter drier damage while brazing filter drier must be wrapped in a heat sinking material such as a wet cloth Install Liquid line Filter Drier Indoor 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 5 in long liquid tube from step 1 4 Connect and braze liquid refrigerant tube to the filter drier Suction Line Filter Drier The suction line drier is specifically designed to operate with Puron use only factory authorized components Suction line filter
2. lt OFF Short Flashes indicate the first digit in the status code followed by long flashes indicating the second digit of the status code FLASH RESET TIME Minimum Minutes 6 N A m 2 Hours 2 Hours 2 Hours 10 2 Hours 340326 101 Table 6 Fault Code Label A Table 7 Fault Code Actions Flash Code Type AMBER LED DESCRIPTION Mode Possible Causes Actions ON no flash Standby 1 pause Variable Capacity 1 2 ON Variable Capacity Range longer pause 1 Cutback second OFF Verify communications wiring ABCD check Loose dew shorted for loose connection stripped wires short to ground or short between wires Wrong Mone eag is Verify correct model plug installed Check model plug for corrosion or breakage 16 Fault COMMUNICATIONS LOSS NA Damaged Model Plug if necessary Data Bus locked up by power loss Cycle Power to system brownout or glitch UI software update Ignore fault in history Sr con Replace AOC control Wrong Model Plug In y 8 stalled 9 Verify correct model plug installed Check model plug for corrosion or breakage 25 System INVALID MODEL NA Both Damaged Mode PUJ replace if necessary Malfunction ot Missing mode
3. C 340614 101 REV A Fig 12 Charging in Cooling Mode 189BNV36 CHARGING IN COOLING MODE 48 Liquid Service Valve Subcooling 8 9 78 6 6 55 44 33 22 65 70 75 80 85 90 95 100 105 36 39 42 44 47 50 53 56 58 Outdoor Ambient Temperature 340615 101 REV A Fig 13 Charging in Cooling Mode 189BNV48 12 SUBCOOLING TEMPERATURE o b a gt 5 a o e o ea e SUBCOOLING TEMPERATURE C Heating Check Chart Procedure See Fig 14 16 Communicating Non communicating Systems In heating mode the required charging method is by weigh in On new installations or complete recharge refer to the unit and indoor fan coil furnace coil per Table 1 for additional charge needed Refrigerant charge adjustment amount for adding or removing 0 6 oz ft 17 74 g m of 3 8 liquid line above or below 15ft 4 57 m respectively Use the Defrost CHECKOUT mode to remove ice or frost from coil if present prior to checking the heating pressures To use the Heating Check Chart the user interface UI must be in Refrigerant Charging mode selected from the Installation and Service screen The Charging Mode Selection screen will show selections for Weigh In Charge Method or Heating Check Charge Method Select Heating Check Charge Method Heating Check Charge method will only be displayed if the conditions are
4. Do not charge if outside 65 F 18 C and 100 F 38 C outdoor temperature If the range is acceptable go the CHARGING screen in the user interface UI At cooling conditions set the user interface UI to check the charge in cooling mode Allow system to operate in cooling mode for the stabilization period as indicated in the user interface UI Once conditions are indicated as favorable and stable by the user interface UI check the system charge by subcooling method Compare the subcooling taken at the liquid service valve to the subcooling target LiqLin SC TGT listed on the charging screen Add refrigerant if the subcooling is low and remove charge if subcooling is high Tolerance should be 2 If any adjustment is necessary add or remove the charge slowly no greater than 0 5 Ib per minute and allow system to operate for 25 minutes to stabilize before declaring a properly charged system The use of a commercial charge metering device restrictor such as Imperial liquid low side charger model 535 C Watsco ChargeFaster model CH200 is recommended when adding refrigerant to an operating system This prevents potential damage of liquid slugging of the compressor and allows the subcooling to stabilize quicker If the indoor temperature is above 80 F 26 67 C and the outdoor temperature is in the favorable range adjust system charge by weight based on line length and allow the indoor temperature to drop to 80 F 2
5. When defrost time 5 minutes the next defrost interval 90 minutes outdoor temperature above 37 F When defrost time 5 7 minutes the next defrost interval 60 minutes When defrost time gt 7 minutes the next defrost interval 30 minutes The control board accumulates compressor run time As the accumulated run time approaches the selected defrost interval time the control board monitors the coil temperature sensor for a defrost demand If a defrost demand exists a defrost cycle will be initiated at the end of the selected time interval A defrost demand exists when the coil temperature is at or below 32 F 0 C for 4 minutes during the interval If the coil temperature does not reach 32 0 C within the interval the interval timer will be reset and start over Upon initial power up the first defrost interval is defaulted to 30 minutes Remaining intervals are at selected times Defrost is only allowed to occur below 50 F 10 C outdoor ambient temperature The defrost cycle is terminated as described below When OAT is gt 25 F 3 89 C defrost terminates if outdoor coil temperature OCT gt 60 F 15 6 C And a minimum of one 1 minute defrost length When OAT 25 F 3 89 defrost will terminate if OCT is gt 45 F 4 4 C and a minimum of 2 minutes defrost length Or 10 minutes has passed At the defrost termination the outdoor fan will turn on 10 seconds before the reversing valve sw
6. right for checking the charge in heating mode When Heating Check Charge Method is selected the system will operate by running in stage 5 with appropriate outdoor fan speed and indoor airflow Upon completion of a countdown period for system stabilization check refrigerant pressures for the appropriate ambient temperatures shown in Fig 14 15 or 16 based the OD unit size To use the Heating Check Chart in non communicating systems operate system at Y1 Y2 high stage These charts indicate whether a correct relationship exists between system operating pressure and air temperature entering indoor and outdoor units If pressure and temperature do not match on chart system refrigerant charge may not be correct DO NOT USE CHART TO ADJUST REFRIGERANT CHARGE NOTE High pressure is at vapor service valve high pressure is taken from liquid service valve NOTE When charging is necessary during heating season charge must be weighed in accordance with unit rating plate 0 6 oz ft x17 74 g m of 3 8 in liquid line above or below 15 ft 4 57 m respectively Add 12 psig if 450 Vapor Service Valve Pressure sv 27 Lm D eer ID 16 C Refrigerant Pressure psig Suction Pressure Heating Check Chart 24 25 For use in Heating Charging Mode only For all AHRI listed indoor combinations 3102 2757 2413 2068 1724 3 Refrigerant Pressure KPa 10 20 120 7 Ou
7. the unit will operate according to the information input at the factory and the appropriate error code will flash temporarily An RCD replacement AOC board contains no model and serial information If the factory control board fails the model plug must be transferred from the original board to the replacement board for the unit to operate When installing heat pump with older fan coils a model plug change may be required NOTE The model plug takes priority over factory model information input at the factory If the model plug is removed after initial power up the unit will operate according to the last valid model plug installed and flash the appropriate fault code temporarily Table 3 Factory Supplied Model Plug Information PIN RESISTANCE MODEL MODEL PLUG K ohms NUMBER NUMBER Pins 1 4 Pins 2 3 288 024 288BNV025 70 2001 5 1K 11K 288BNV036 HK70EZ002 5 1K 18K 288BNV048 HK70EZ003 5 1K 24K 189BNV024 189BNV025 70 2011 5 1K 120K 189BNV036 HK70EZ012 5 1K 180K 189BNV048 HK70EZ013 5 1K 220K Status Codes Table 6 shows the status codes flashed by the amber status light Most system problems can be diagnosed by reading the status code as flashed by the amber status light on the control board The codes are flashed by a series of short and long flashes of the status light The short flashes indicate the first digit in the status code followed by long flashes indicati
8. 1 2 3 4 5 6 7 8 9 10 11 12 14 N N N A 1 8 9 B N V 0 3 6 0 0 0 A Product Tier SEER Major Voltage Variations Cooling Capacity Open Open Open Series Family Series 1 8 9 19SEER B Puron N 208 230 1 V Variable 0 0 0 A Evolution or 208 230 1 Speed Defined Defined Defined Original Series Series SERIAL NUMBER NOMENCLATURE 01 Week of Manufacture Year of Manufacture 06 00001 Serial Number Manufacturing Site E Collierville TN X Monterrey Mexico REFRIGERANT PIPING LENGTH LIMITATIONS Maximum Line Lengths The maximum allowable total equivalent length varies depending on the vertical separation See the tables below for allowable lengths depending on whether the outdoor unit is on the same level above or below the outdoor unit Maximum Line Lengths MAXIMUM ACTUAL LENGTH MAXIMUM EQUIVALENT LENGTHT MAXIMUM VERTICAL SEPARA ft m ft m TION ft m Units on equal level 100 30 5 100 30 5 N A Outdoor unit ABOVE indoor unit 100 30 5 100 30 5 100 30 5 See Table Maximum Total Equivalent Length Outdoor Unit BELOW Indoor Unit T Total equivalent length accounts for losses due to elbows or fitting See the Long Line Guideline for details Maximum Total Equivalent Length Outdoor Unit BELOW Indoor Unit Liquid Li Maximum Total Equivalent Lengtht Si eee Vertical Separation ft m Outdoor unit BELOW indoor
9. 10 gt a 175 97 m 94 2 17 2 S 165 92 8 E m gt a 16 89 2 15 5 8 6 15 8 3 65 TO 75 80 85 90 85 100 105 110 115 36 C 39 C 42 C 44 47 50 53 56 58 C 61 C 64 C Outdoor Ambient Temperature F C Fig 9 Charging in Cooling Mode 288BNV36 CHARGING IN COOLING MODE 48 Liquid Service Valve Subcooling 13 5 7 5 13 72 e 8 125 69 ge B i 5 4 67 2 S e e e e o a EI e 115 11 6 11 65 70 75 80 85 90 95 100 105 110 115 36 39 42 44 C 47 C 50 C 53 C 56 C 58 C 61 64 C C Outdoor Ambient Temperature F C J Fig 10 Charging in Cooling Mode 288BNV48 11 SUBCOOLING TEMPERATURE SUBCOOLING TEMPERATURE F SUBCOOLING TEMPERATURE 12 10 CHARGING IN COOLING MODE 24 25 Liquid Service Valve Subcooling 6 6 55 44 33 22 14 65 70 75 80 85 90 95 100 105 36 39 42 C 44 C 47 C 50 53 56 58 Outdoor Ambient Temperature 340769 101 REV A Fig 11 Charging in Cooling Mode 189BNV24 25 CHARGING IN COOLING MODE 36 Liquid Service Valve Subcooling 8 9 7 8 6 6 55 44 33 22 65 70 75 80 85 90 95 100 105 36 39 42 44 47 50 53 56 58 Outdoor Ambient Temperature F
10. A CNPV 42 Nameplate N A N A CAP 42 Nameplate N A N A CNPV 48 0 75 Nameplate N A CAP 48 0 75 Nameplate N A CSPH 48 0 75 Nameplate N A F E V 4 A B C N B F 005 0 75 Nameplate N A CNPV 60 N A Nameplate Nameplate CSPH 60 N A Nameplate Nameplate CAP 60 N A 2 2 1 3 4 006 42 2 413 Table 2 Required Charge Adjustment for Indoor Coil Model AC Furnace or Fan Coil 189BNV Model Number 024 amp 025 036 048 CNP 24 CSPH 24 CAP 24 F E V 4 A B C NF002 F E V 4 A B C N B F 003 4 5 CAP 30 T5 CNP 30 T5 CAP 36 T5 CNP 36 T5 CSPH 36 T5 CNP 42 T5 CAP 42 T5 CNP 48 CNP 37 1 25 75 CNP 43 1 25 75 CAP 48 CNP 60 CSPH 60 CAP 60 41 5 F E V 4 A B C N B F 005 41 5 CNP 61 1 5 F E V 4 A B C NBOO6 15 10 SUBCOOLING TEMPERATURE F CHARGING IN COOLING MODE 24 25 Liquid Service Valve Subcooling For all AHRI listed indoor combinations 14 13 5 13 12 5 12 11 5 11 10 5 SUBCOOLING TEMPERATURE C 10 9 5 65 70 75 80 85 90 95 100 105 36 39 C 42 44 47 50 53 56 58 Outdoor Ambient Temperature F C Fig 8 Charging in Cooling Mode 288BNV24 25 CHARGING IN COOLING MODE 36 Liquid Service Valve Subcooling For all AHRI listed indoor combinations 20 11 1 19 5 10 8 19 10 6 u 18 5 103 LL
11. CHOKE BLK MOTOR amp COMPRESSOR CONTROL SECTION MOTOR CONTROL CO SW 30 60 60 30 i 90 J2 FORCED DEFROST YEL BLK GRN TB 23 1 1 Lat L2 UJ 208 230 19 POWER SUPPLY 21 1 12 HP CONTROL PL10 M HEADER COMM HEADER RVS PEV 9 j ORG ORG BLU BLU RVS PEV HEAT PUMP mmm mmm STATUS COMM SPT CONTROL SECTION DC HPS HPS BLU BLU PNK BLU BLU PNK A BLU EXV 0 ee 1 UTILITY INTERFACE CHOKE To EQuiP GND OCT OAT MODEL PLUG CHART MODEL SIZE MODEL PLUG HK70EZ PIN RESISTANCE K 1 4 81 2 3 R2 24 001 11 25 001 11 36 002 18 48 003 24 60 004 33 UNIT OPERATION This control board contains a 3 5 minute short cycle protector A 3 5 minute delay will occur between Compressor offlon cycles To bypass delay short forced defrost pins for 1 second then release However there is an additional 2 5 minutes delay upon expiration of the 3 5 minute short cycle delay to ensure the high and low side pressures are equalized This is important for long term rotary compre
12. Conductors Only Use Conductors Suitable For At Least 75 C 167 F 3 4 e Will Two Wire A and B Required For Communication If Outdoor Unit Improperly Grounded Connect Indoor Ground To C Terminal If Any Of The Original Wire As Supplied Must Be Replaced Use The Same Or Equivalent Wire Check All Electrical Connections Inside Control Box For Tightness Do Not Attempt To Operate Unit Until Service Valves Have Been Opened If Communicating Must Use With Infinity or Evolution User Interface Listed In Pre sale Literature Only For Non Communicating Thermostats 24VAC To Be Provided To R Connection N E C class 2 24 V circuit min 40 VA required 60 VA on units installed with LLS LEGEND FACTORY POWER WIRING ELD POWER WIRING ACTORY CONTROL WIRING ELD CONTROL WIRING OMPONENT CONNECTION UNCTION ELD SPLICE LUG CONNECTION YSTEM COMMUNICATION OMPRESSOR LECTRONIC EXPANSION SW2 VOLTAGE INDICATOR LED TB H PRESSURE SWITCH UTIL UTILITY CURTA OW VOLTAGE CHOKE HARNESS 24V 24 VOLTS DC MAY BE FACTORY OR FIELD INSTALLED MODEL MODEL PLUG OAT OUTDOOR AIR THERMISTOR OCT OUTDOOR COIL THERMISTOR ODT OUTDOOR DISCHARGE THERMISTOR OFM OUTDOOR FAN MOTOR OST OUTDOOR SUCTION THERMISTOR PEV PRESSURE EQUALIZER VALVE RVS REVERSING VALVE SOLENOID SPT SUCTION PRESSURE TRANSDUCER SYSTEM FUNC DEFROST TIME e ION LIGHT SELECT STATUS TERMINAL BLOCK LMENT
13. LI Imo ec 339885 101 REV D J Fig 21 288BNV WIRING DIAGRAM 31 REFRIGERATION SYSTEM Refrigerant 4 WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury or equipment damage Puron refrigerant which has higher pressures than R 22 and other refrigerants No other refrigerant may be used in this system Gauge set hoses and recovery system must be designed to handle Puron If you are unsure consult the equipment manufacturer In an air conditioning and heat pump system refrigerant transfers heat from one replace to another The condenser is the outdoor coil in the cooling mode and the evaporator is the indoor coil In a heat pump the condenser is the indoor coil in the heating mode and the evaporator is the outdoor coil In the typical air conditioning mode compressed hot gas leaves the compressor and enters the condensing coil As gas passes through the condenser coil it rejects heat and condenses into liquid The liquid leaves condensing unit through liquid line and enters metering device at evaporator coil As it passes through metering device it becomes a gas liquid mixture As it passes through indoor coil it absorbs heat and the refrigerant moves to the compressor and is again compressed to hot gas and cycle repeats Compressor Oil CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper
14. The technician performing the service must determine that it is safe to work on or near the inverter The electrical disconnect that provides power to the unit must be turned off locked and tagged out This will insure that no damage will occur to the inverter controls or other equipment and will prevent injury if contact is made with the electrical equipment Wait a minimum of two minutes before servicing the unit to allow inverter capacitors to discharge Follow safety instructions located on unit control box cover 3 Remove and recover all refrigerant from system until pressure gauges read 0 psi Use all service ports Never open a system under a vacuum to atmosphere Break vacuum with dry nitrogen holding charge first Do not exceed 5 psig 4 Remove the control box cover 5 Disconnect compressor power harness from inverter 6 Remove service panel to gain access to unit wiring and compressor compartment 27 7 Cut the wire tires securing the compressor power harness to the control box Remove compressor power harness from control box Replace wire tie with one supplied do not fasten at this time The second wire tie for the choke on the compressor is supplied with new harness on the replacement compressor highlighted with the yellow circles below 8 Remove top two screws holding control box and remove compressor harness highlighted in yellow below Sam 9 Cut double loop wire tie on suction tube holdi
15. Unit Airflow Troubleshoot indoor fan motor and make sure 9 too low or off it is working Both Outdoor Unit Airflow Troubleshoot outdoor fan motor and make too low or off sure it is working Both paa By Reversing Valve Stuck halfway DISCHARGE TEMP OUT OF 59 Event ix ANGE ENT 2 15 Min Cool High Load conditions Over charge Check system charge Low Charge or Loss Heat 2 Undercharged or charge check charge tions Heat Expansion Valve Ori Heating Trouble shoot EXV coil harnesses fice too small Trouble shoot the TXV OFM failed to start Troubleshoot outdoor fan motor amp blade and 61 Fault FAN INVERTER FAULT 6 Min Both make sure they are working Possible nuisance trip System will try to self mitigate Unusual loading of Troubleshoot outdoor fan motor amp blade and the fan make sure they are working 62 Fault 6 Min Both Check for fan outlet blockage due to snow ice TURE HIGH Improper airflow etc across vee Heat sink Inspect outdoor coil for obstructions Sudden supply volt i vestiqats iacernin FAN INVERTER OVER CUR Aue Sop age change ag Orage au RENT n 9 Sudden load change Troubleshoot outdoor fan motor amp blade and on fan motor make sure they are working 65 Fault DC VOLTS LOW FAULT 6 Min Both Possible nuisance trip m o mitigate Witiy speed OUTDOOR FAN DROPPED MOC is reporting that Troubleshoot outdoor fan motor and make Fault OUT 6 Min Both OFM isn
16. and cooling modes is accomplished with a valve that reverses flow of refrigerant in system This reversing valve device is easy to troubleshoot and replace The reversing valve solenoid can be checked with power off with an ohmmeter Check for continuity and shorting to ground With control circuit 24v power on check for correct voltage at solenoid coil Check for overheated solenoid With unit operating other items can be checked such as frost or condensate water on refrigerant lines The sound made by a reversing valve as it begins or ends defrost is a whooshing sound as the valve reverses and pressures in system equalize An experienced service technician detects this sound and uses it as a valuable troubleshooting tool Using a remote measuring device check inlet and outlet line temperatures DO NOT touch lines If reversing valve is operating normally inlet and outlet temperatures on appropriate lines should be close to each other Any difference would be due to heat loss or gain across valve body Temperatures are best checked with a remote reading electronic type thermometer with multiple probes Route thermocouple leads to inside of coil area through service valve mounting plate area underneath coil Fig 22 and Fig 23 show test points TP on reversing valve for recording temperatures Insulate points for more accurate reading If valve is defective 1 Shut off all power to unit and remove charge from system 2 Remove
17. low side pressures are equalized This is important for long term rotary compressor U RED reliability It is a delay that cannot and must not be bypassed The internal crankcase heater is energized YEL SV during off cycle as needed 1 YEL RED BK CHOKE CHOKE YE RED a RER U DC pct LD1 DC FAN MOTOR amp COMPRESSOR CONTROL SECTION HPS e BU BLU PNK FL ej BLU sum 6 MOTOR CONTROL COMM HEADER HP CONTROL COMM HEADER NOTES FUSE 3AMP RVS PEV 1 To Be Wired In Accordance With National Electric Code N E C And Local Codes ej 2 Use Copper Conductors Only Use Conductors Suitable For At Least 75 C 167 F 3 Two Wire A and B Required For Communication If Outdoor Unit Improperly m 120 o EM Grounded Connect Indoor Ground To C Terminal soL_tso QE BLU BLU 4 f Any Of The Original Wire As Supplied Must Be Replaced Use The Same NC Equivalent Wire PL19 5 Check All Electrical Connections Inside Control Box For Tightness al mm e BLK ST 6 Do Not Attempt To Operate Unit Until Service Valves Have Been Opened mE STATUS COMM wr 7 If Communicating Must Use With Infinity or Evolution User Interface Listed In DEFROST PEV TL pen Pre sale Literature Only PL17 ALK 8 For Non Communicating Thermostats 24VAC To Be Provided To R Connection YEL AIR CONDITIONER ost 9 class 2 24 V circuit min 40 VA required 60 VA on units installed with LLS CONTROL SECTION e BLK BK i e OST
18. lubricant run offs through the louvered openings in the base pan 4 Perform required service 5 Remove and dispose of any oil contaminated material per local codes Brazing This section on brazing is not intended to teach a technician how to braze There are books and classes which teach and refine brazing techniques The basic points below are listed only as a reminder Definition The joining and sealing of metals using a nonferrous metal having a melting point over 800 426 6 Flux A cleaning solution applied to tubing or wire before it is brazed Flux improves the strength of the brazed connection When brazing is required in the refrigeration system certain basics should be remembered The following are a few of the basic rules 1 Clean joints make the best joints To clean Remove all oxidation from surfaces to a shiny finish before brazing Remove all flux residue with brush and water while material is still hot 2 Silver brazing alloy is used copper to brass copper to steel or copper to copper Flux is required when using silver brazing alloy Do not use low temperature solder 3 Fluxes should be used carefully Avoid excessive application and do not allow fluxes to enter into the system 4 Brazing temperature of copper is proper when it is heated to a minimum temperature of 800 F and it is a dull red color in appearance Service Valves and Pumpdown 4 WARNING PERSONAL INJURY AND UNIT D
19. 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 fitings and connections in system Leak is detected by either the movement of a pointer on detector dial a buzzing sound or a light In all instances when a leak is found system charge must be recovered and leak repaired before final charging and operation After leak testing or leak is repaired replace liquid line filter drier evacuate system and recharge with correct refrigerant quantity a WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label Coil Removal Coils are easy to remove if required for compressor removal or to replace coil 1 Shut off all power to unit Recover refrigerant from system through service valves Break vacuum with nitrogen Remove top cover Remove screws in base pan to coil grille Remove coil grille from unit RU Remove screws on corner post holding coil tube sheet 4 WARNING FIRE HAZARD Failu
20. pressure Extreme caution should be observed when handling refrigerants Wear safety glasses and gloves to prevent personal injury During normal system operations some components are hot and can cause burns Rotating fan blades can cause personal injury Appropriate safety considerations are posted throughout this manual where potentially dangerous techniques are addressed If you do not understand any of the warnings contact your product distributor for better interpretation of the warnings GENERAL INFORMATION The 288BNV amp 189BNV split system heat pump and air conditioners features a new outdoor cabinet design that uses a four sided coil design to minimize the unit footprint and provide the best heat exchange taking full advantage of the latest variable speed technology The heart of the system is the variable speed rotary compressor powered through the use of the variable speed drive VSD inverter control Through the use of Puron refrigerant compact ECM outdoor fan motor VSD and variable speed scroll compressor along with the new outdoor cabinet the unit achieves a Seasonal Energy Efficiency Ratio SEER of up to 19 and up to 11 Heating Seasonal Performance Factor HSPF To ensure ultimate comfort these units should be combined with either the FE fan coil or Variable Speed Gas furnace controlled with a two wire communication Evolution Connex Control SYSTXBBITNO1 SYSTXBBITCO1 or SYSTXBBITWOI with Version 11 softwar
21. service valves are open Replacement Procedure 1 Follow all safety warnings and notices 2 Precautions must be taken when servicing components within the control box of this unit The technician performing the service must determine that it is safe to work on or near the inverter The electrical disconnect that provides power to the unit must be turned off locked and tagged out This will insure that no damage will occur to the inverter controls or other equipment and will prevent injury if contact is made with the electrical equipment Wait a minimum of two minutes before servicing the unit to allow inverter capacitors to discharge Follow safety instructions located on unit control box cover 3 Remove the control box cover 4 Disconnect compressor power harness from inverter 5 Remove service panel to gain access to unit wiring and compressor compartment 6 Cut the wire tires securing the compressor power harness to the control box Remove compressor power harness from control box Replace wire tie with supplied wire tie do not fasten at this time The second wire tie for the choke on the compressor is supplied with new harness on the replacement compressor highlighted with the yellow circles below 7 Remove top two screws holding control box and remove compressor harness highlighted in yellow below 5 af t 8 Cut double loop wire tie on suction tube holding compressor harness replace with
22. supply voltage to ODU if low contact age 197 VAC utility provider Storm weather caus pd When adverse weather subsides unit should VDC UNDER VOLTAGE ing intermittent voltage 4 96 LOCKOUT lockout occurs af 2 Hours Both dropouts Sell recover cyclo DONEC necessary ter repeated 93 faults Loose wire in control Loose wire check for loose wire in ODU box area Inverter pie dam Replace Inverter High supply line volt Check supply voltage to ODU if high contact age 253 VAC utility provider VDC OVER VOLTAGE LOCK Storm weather caus 97 Mal OUT lockout occurs after re 2 Hours Both ing intermittent voltage When adverse weather Subsides nction self recover cycle ODU power if necessary peated 94 faults spikes Inverter internal dam Replace Inverter age Compressor is operat ot N nverter will reduce speed to a lower stage Both operational en verter wil reduce speed to a lower stag 98 Event HIGH TORQUE EVENT 10 Min vean Both Mis wire Check mis wire of compressor leads at termi nals U V W Both Incorrect refrigerant Check refrigerant amount charge Check ODU coil for clogging or debris and 99 System Mal HIGH TORQUE LOCKOUT 2 hours Both Outdoor IIO TOS clean if necessary Troubleshoot ODU fan motor function low or off n and make sure it is working Cool TXV issue Troubleshoot TXV Heat EXV issue Troubleshoot EXV 21 Variable Speed Drive
23. t running sure it is working There is a demand for Check compressor winding resistance or 67 Fault STATOR HEATER FAULT 6 Min Both stator heat but MOC mis wire of compressor leads at terminals doesn t detect it U VW Check compressor winding resistance or Phase imbalance mis wire of compressor leads at terminals U VW 69 S op 15 Inverter damage Replace inverter Flooded start Troubleshoot EXV amp TXV Incorrect refrigerant charge Check refrigerant amount COMPRESSOR DROPPED is reporting that Check compressor winding resistance or 71 Fault 6 Min Both compressor isn t run mis wire of compressor leads at terminals OUT ning U VW 18 Table 7 Fault Code Actions continued Flash Reset Type AMBER LED DESCRIPTION Mode Possible Causes Actions Code Time Both Incorrect refrigerant charge Check refrigerant amount Cool Uninsulated vapor line Insulate the vapor line 72 Fault SUETON OVSE 15 Min Cool Indoor TXV operation Troubleshoot TXV Heat Outdoor EXV operation Troubleshoot EXV Both Reversing valve bypass troubleshoot reversing valve DISCHARGE TEMP OUT OF System Mal RANGE LOCKOUT lockout 74 function occurs after 59 fault repeats 2 Hours Both See fault 59 Same actions for 59 and stage can no longer be lowered MAXIMUM POWER MODE Check ODU co
24. the inverter controls or other equipment and will prevent injury if contact is made with the electrical equipment Remove the control box cover The inverter capacitors are covered with a protective shield The shield should not be removed from the inverter Before servicing the inverter verify the inverter voltage is zero Measure the DC voltage at the DC VOLTAGE and DC VOLTAGE terminals on the inverter adjacent to the capacitors to ensure that they have totally discharged The voltage at these terminals must be 0 zero before servicing see following figures Compressor Power Harness Wires Yel Red Blk 6 After verifying the voltage has dissipated to zero 14 Disconnect discharge thermistor plug disconnect wiring from the inverter 15 Disconnect OAT OCT plug 7 Disconnect three compressor power wires Note wire color 16 Disconnect control wiring ABCD thermostat order Yellow Red and Black connections 8 Disconnect fan motor power harness plug 17 Disconnect two input power wires Note wire color order 9 Disconnect reversing valve PEV plug See Figure Below Black and Yellow 10 Disconnect high pressure switch plug 18 Disconnect inverter ground lead Note wire color Green 11 Disconnect EXV plug w Yellow Stripe 12 Disconnect suction pressure transducer plug 19 Remove 12 mounting screws and pull out inverter with 13 Disconnect suction thermistor plug coyerantact Reversing
25. the outdoor air sensor indicates gt 25 F gt 15 C cooler than the coil sensor the sensors are out of range In heating if the outdoor air sensor indicates 35 F gt 19 4 C warmer than the coil sensor or the outdoor air sensor indicates 10 F gt 5 6 C cooler than the coil sensor the sensors out of range If the sensors are out of range the control will flash the appropriate fault code as shown in Table 6 The thermistor comparisons are not performed during low ambient cooling or defrost operation Failed Thermistor Default Operation Factory defaults have been provided in the event of failure of outdoor air thermistor OAT and or outdoor coil thermistor OCT If the OAT sensor should fail defrost will be initiated based on coil temperature and time If the OCT sensor should fail defrost will occur at each time interval during heating operation but will terminate after 2 minutes If there is a thermistor out of range error defrost will occur at each time interval during heating operation but will terminate after 2 minutes Count the number of short and long flashes to determine the appropriate flash code Table 6 gives possible causes and actions related to each error SERVICE AMBER LED DESCRIPTION CODE Amber LED Variable Ca ed 1 pause Variable 1 2sec ON geed longer pause Cu second OFF Communications Loss Invalid Model High Pressure Swi
26. to the terminals marked A and B on the terminal strip located in the bottom left corner of the AOC board see Fig 17 But instead of connecting the wires on the service tool to the terminals marked C and D connect the C and D wires from the service tool to the two terminals of the 120VAC to 24VAC adapter 0 5Amp minimum as shown in Fig 17 When the service tool is connected and powered up the communicating controls inside the home will go to sleep and let the service tool take control of the system In this manner the service technician can run the diagnostic checkouts right at the outdoor unit using the service tool After the checkouts are completed and it is no longer necessary to use the service tool remove it from the communicating controls and the indoor communicating controls will regain control in about two minutes Systems Communication Failure If communication is lost with the User Interface UT the control will flash the appropriate fault code see Table 6 Check the wiring to the User Interface and the indoor and outdoor units and power Model Plug Each control board contains a model plug The correct model plug must be installed for the system to operate properly see Table 3 The model plug is used to identify the type and size of unit to the control On new units the model and serial numbers are inputted into the AOC board s memory at the factory If a model plug is lost or missing at initial installation
27. 288BNV EVOLUTION V VARIABLE SPEED HEAT PUMP 189BNV EVOLUTION V VARIABLE SPEED AIR CONDITIONER WITH PURON REFRIGERANT Service Manual TABLE OF CONTENTS PAGE UNIT IDENTIFICATION eee EE ROE MERE OR EELS EE Aa DIAS ERA RR RU CERES 2 REFRIGERANT PIPING LENGTH 8 2 2 3 LONG LINE APPLICATIONS ggg s uer ea Eee e SEW NEES Aa aS 3 SAFETY CONSIDERATIONS 222222252222 ERA ERES E Eee E eus 4 GENERAL INFORMATION 2 eects ee EUR EROR E E Rh d 4 ELECTRICAL ERR tE ERSEN SAAREEN EURER ESERE EE EEEO ANE ARENE NS ENESA EENE SE ERE eRe 5 MAJOR COMPONENTS et kt pea Y GRRRRRREERIURRRAETRUARRO dee HAGLER AOE Hele EEEE er d pd 5 7 AOC Board ELTE 5 l 5 Variable Speed COmptessOr ds ose e RD ER DERE ME br RI ER C E E etka ties tea IE E EPI TURA ES 5 Electronic Expansion Valve EXP 500 5 sects ruere Rex Ee 60 0 VERO Gee NUN RES Sce e eR 6 Outdoor Fan Motors UO Reb E E EY RARE NE 6 Pressure SPT sone RA ER REESE EE
28. 6 Pressure Equalizer ICE eO ace quee qune SN EI KR 6 Outdoor Coil Thermistor OCT 55556 Mere eoe es eser Pe or sue E m NE a ed 6 Suction Thermistor OST Res carne Gains Vins Seige DERE RR Hales UNE eA RUN 7 Discharge Thermistor ODT 225252942 eue RR UC a ERR EE RR re EIE ELE Ra 7 Crankease Heater za sede toe tee OC SIC E e pedro S A e ed eae nd qe Sce bue d Ree ed 7 Time Delays UR EDUCERER ES EEG RAN RR Ee DIEN d 7 COMMUNICATION AND STATUS FUNCTION LIGHTS 7 siss as angan aa Ce ET EC QU doe DO HEUS 9 TROUBLESHOOTING bebe REA tepe E MES egt ee bee ka EA Y aede ena 14 27 Service Tool iiec ee need ER eines ERE v RH E tne ECHO RR OTRA KR Gee E ER HR EN Races v Bina ES 14 System Communication te BOCA euius He eee Se deus Race does 14 Model RIG ERI ER 14 Status Codes scere EP Re OUT eee edie gee enue hed ted okie PIER tees Hee Kew s 14 Variable Speed Compressor Winding Resistance 2 14 Mot
29. 6 67 C before attempting to check system charge by subcooling method as described above If the indoor temperature is below 70 F 21 11 C or the outdoor temperature is not in the favorable range adjust charge for line set length above or below 15ft 4 57 m and indoor fan coil furnace coil per Table 1 and 2 Charge level should then be appropriate for the system to achieve rated capacity The charge level could then be checked at another time when the both indoor and outdoor temperatures are in a more favorable range This ensures maximum efficiency and reliability Charging Non Communicating Systems Charging Procedure Force system to operate in high stage cooling by creating a large differential between room temperature and set point on thermostat Use multi meter to verify that 24 VAC is present between C Y1 Y2 terminals at outdoor unit Factory charge amount is shown on unit rating plate for high stage Target subcooling chart is provided on back of control box door see Fig 8 10 for example To properly check or adjust charge condition must be favorable for subcooling charging Favorable conditions exists when outdoor temperature is between 65 18 C and 100 38 C and the indoor temperature is between 70 F 21 C and 80 F 27 C Follow the procedure below Unit is factory charged for 15ft 4 57 m of lineset Adjust charge by adding or removing 0 6 oz ft 17 7 g m of 3 8 liquid line above or below 15ft 4 5
30. 7 m respectively For standard refrigerant line lengths 80ft 24 4 m or less allow system to operate in cooling mode at least 25 minutes If conditions are favorable check system charge by subcooling method If any adjustment is necessary adjust charge slowly and allow system to operate for 25 minutes to stabilize before declaring a properly charged system If the indoor temperature is below 70 F 21 11 C or the outdoor temperature is not in the favorable range adjust charge for line set length above or below 15ft 4 57 m and indoor fan coil furnace coil per Table 1 for HP and Table 2 for AC Charge level should then be appropriate for the system to achieve rated capacity The charge level should then be checked at another time when the both indoor and outdoor temperatures are in a more favorable range NOTE If the line length is beyond 80ft 24 38 m or greater than 20ft 6 10 m vertical separation see Long line guideline for special charging requirement Table 1 Required Charge Adjustment for Indoor Coil Model HP Required Charge Adjustment for Indoor Coil Model Model Number 25VNA836A003 25VNA848A003 25VNA860A003 CNPV 36 Nameplate N A N A CAP 36 Nameplate N A N A CSPH 36 Nameplate N A N A F E V 4 A B C NF002 Nameplate N A N A F E V 4 A B C N B F 003 Nameplate N A N
31. A Both ness wire should be 10 kOhm Broken or Damaged Check harness for continuity resistance Sensor should be in 10 kOhm Hardware damage to control Replace AOC control Sensor Harness not connected to AOC Ensure plug is connected to AOC control control Broken or loose har Check harness for continuity resistance 53 Fault P SEN NA Both ness wire should be in 10 kOhm Broken or Damaged Check harness for continuity resistance Sensor should be in 10 kOhm Hardware damage to AOC control Replace AOC control Sensor Harness not connected to AOC Ensure plug is connected to AOC control control Broken or loose har Check harness for continuity resistance ness wire should be in 10 kOhm 54 Fault SUCTION TEMP SENSOR NA Both Suction Thermistor Ensure Sensor is properly attached to the ac FAULT not properly attached cumulator entry tube or in wrong location y Broken or Damaged Check harness for continuity resistance Sensor should be in 10 kOhm Hardware damage to control Replace AOC control 17 Table 7 Fault Code Actions continued Reset Flash Code Type AMBER LED DESCRIPTION Time Mode Possible Causes Actions Sensor Harness not connected to AOC Ensure plug is connected to AOC control control Broken or loose har Check harness for continuity resistance ness wire should be 10 kOh
32. AMAGE HAZARD Failure to follow this warning could result in personal injury or equipment damage Never attempt to make repairs to existing service valves Unit operates under high pressure Damaged seats and o rings should not be replaced Replacement of entire service valve is required Service valve must be replaced by properly trained service technician Service valves provide a means for holding original factory charge in outdoor unit prior to hookup to indoor coil They also contain gauge ports for measuring system pressures and provide shutoff convenience for certain types of repairs The service valve is a front seating valve which has a service port that contains a Schrader fitting The service port is always pressurized after the valve is moved off the front seat position The service valves in the outdoor unit come from the factory front seated This means that the refrigerant charge is isolated from the line set connection ports The interconnecting 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 valve the belled ends of the sweat connections on the service valves must be cleaned so that no brass plating remains on either the inside or outside of the bell joint To prevent damage to the valve and or cap O ring use a wet cloth or other acceptable heat sinking material on the valve before brazing To prevent damage
33. Fs RA H e 14302 Fig 2 HP Outdoor Coil Thermistor OCT Attachment On Distributor Tube P H OCT Sensor mal igl Location 5 H r1 A co 0 H o 0 B co us N N oJ RE 14328 Fig 3 AC Outdoor Coil Thermistor OCT Attachment On Distributor Tube OAT Thermistor must be locked in place with spherical nib end facing towards the front of the control box Y A11142 Fig 4 OAT Thermistor Location Bottom of Control Box Suction Thermistor OST Suction Thermistor is used for assisting in EXV control and must be secured on the suction tube and aligned longitudinally to the vertical surface of the tube axis see Fig 5 A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation In order to minimize the ambient influence make sure the thermistor curved surface hugs the pipe surface and is secured tight using the wire tie fished through the original slot insulating polymer body A14023 Fig 5 Suction Thermistor OST Attachment On Suction Tube Discharge Thermistor ODT Discharge Thermistor is used for pro
34. LED Location and Description MOC LED Description Reference Color Status Description Steady On MOC powered where DC bus is 40volts or greater LD1 Red Off No power capacitor voltage drained Steady On DCF and board DC high voltage and discharge circuit powered on LED1 Red Off No power Steady On MOC board switching power supply to power AOC board on LED3 Amber Off No Power Blinking Indicates communication from MOC to AOC Steady On Indicates 5 volt connection status OK between AOC and LD5 Green Off No Power AOC LED Descriptions Reference Color Status Description Steady On AOC status standby mode AT A STATUS mber Blinking AOC function fault status COMM Green Steady On Communication from AOC to indoor wall control LED Not Functioning Properly Requires AOC Replacement Reference Color Suspect AOC board Failure Description STATUS Amber If Amber STATUS light is not on neither steady nor blink AOC STATUS is not functioning properly and AOC board ing with power to outdoor unit should be replaced In Communicating mode if Green COMM LED is not on COMM Green when AB indoor wires are connected to AOC AB connector POUR DP WIE MIO COS AQE and indoor has communications board should be replaced Fault Codes requiring AOC Replacement Fault Code Description Fault Flash Code Failure Desc
35. LEGEND FACTORY POWER WIRING MODEL MODEL PLUG PU FIELD POWER WIRING OAT OUTDOOR AIR THERMISTOR MODEL ODT FACTORY CONTROL WIRING OCT OUTDOOR COIL THERMISTOR PL18 tLe BEK c FIELD CONTROL WIRING ODT OUTDOOR DISCHARGE THERMISTOR PL15 COMPONENT CONNECTION OFM OUTDOOR FAN MOTOR 47 24V UTILC R Y Y WO OCT OAT JUNCTION OST OUTDOOR SUCTION THERMISTOR 47 FIELD SPLICE PEV PRESSURE EQUALIZER VALVE lt lt PLUG CONNECTION SPT SUCTION PRESSURE SI TRANSDUCER 51 uu BRN COMM SYSTEM COMMUNICATION STATUS SYSTEM FUNCTION LIGHT EU BRN BLK COMP COMPRESSOR Sw2 DEFROST TIME SELECT py tell UTILITY INTERFACE LD1 HIGH VOLTAGE INDICATOR LED TERMINAL BLOCK 5 HIGH PRESSURE SWITCH UTIL UTILITY CURTAILMEN BET LVCH LOW VOLTAGE CHOKE HARNESS 24 24 VOLTS DC 1 ggu MAY BE FACTORY OR FIELD INSTALLED GRN LVCH MODEL PLUG CHART T8 GND MODEL MODEL PIN RESISTANCE 211 123 SIZE PLUG 1 HK70EZ 1 4 1 2 3 R2 ut 0 24 011 5 1K 150K LU 25 011 5 1K 150K 208 230 10 POWER SUPPLY 36 012 5 1K 180K 48 013 51K 220K 340613 101 REV J Fig 20 189BNV WIRING DIAGRAM 30 M CHOKE e 46 tei 26 CONNECTION DIAGRAM oct LD1 DC FAN FUSE 120 RU Ow Sv YEL RED YEL RED UNI BLK
36. R UN HS 32 Compressor OREMUS 32 Servicing Systems on Roofs With Synthetic Materials 32 Incun MEET 32 Service Valves and P mp dOWn gt express ey m ee ace uie Deu Ree e e D e aeg 32 Liquid Lime Filter Drier au neri Waki ree gu teg c ft RO UD Gain Mc 35 Suction Line Filter DrieT cu sve RR ELS bg been gb SERO ORG SERO RR RU A ER ELE RR Le ERA ADR cR 35 Thermostatic Expansion Valve LXV be She ere eee sad S Rete RR Reg Re Race prr pe Pede Neve des 35 ACCUMUIAOL I 36 REFRIGERATION SYSTEM REPAIR 36 UNIT IDENTIFICATION The unit is identified using a 16 digit model number structure It is recommended providing the complete 16 digit model number when ordering replacement parts to insure receiving the correct parts MODEL NUMBER NOMENCLATURE HEAT PUMP 1 2 3 4 5 6 7 8 9 10 11 12 14 N N N A 2 8 8 B N V 0 3 6 0 0 0 A Product Tier SEER Major Voltage Variations Cooling Capacity Open Open Open Series Family Series 2 HP 8 8 18SEER B Puron N 208 230 1 V Variable 0 Not Oz Not 0 Not Evolution or 208 230 1 Speed Defined Defined Defined Original Series Series MODEL NUMBER NOMENCLATURE AIR CONDITIONER
37. TEMP 82 f LOCKOUT lockout occurs af 4 Hours Both See fault 72 Same actions for 72 unction ter 72 fault repeats 3X Cooling in Low Ambient re Coo ATHE Enable Low Ambient Cooling via user interface trol disabled Outside Normal Operating Range e g improper load Coo calculation system match is Consult Application Guidelines Sue outside cooling range etc Coo Ss valve left closed Liq Ensure Service Valves are open uid or Vapor Check system subcooling to determine charge sta Coo Undercharged System tus if low add charge using Charging Mode follow proper charging procedures Check Indoor for clogging ice or debris and clean Coo Indoor Airflow too low or off or de ice if necessary Troubleshoot Indoor fan mo tor and make sure it is working follow Indoor Airflow troubleshooting instruction Hestnction in riter Drier plus Clean System refer to application guideline and Coo Long Line Application and fil i replace filter drier ter drier on Indoor Unit Coo Restriction due to debris Clean System refer to application guideline and replace filter drier System Mal LOW PRESSURE LOCKOUT Restriction or Tub Check kinks and straighten or replace circuits e function ET oe ae at Hours Both Restriction in Filter Drier plus Clean System refer to application guideline and filter drier on Outdoor Unit replace filter drier Both Expansion Orifice Restriction If short lineset less than 15ft Troublesh
38. Valve and PEV Plug Inverter Ground Wire Grn W Yel Stripe Inverter Input Power Wires and Blu High Pressure Switch Plug EXV Plug Suction Pressure Transducer Plug Suction Thermistor Plug Discharge Thermistor Plug OAT OCT PLUG Installing New Inverter IMPORTANT DO NOT USE POWER TOOLS TO 26 Re connect suction thermistor plug TIGHTEN THE INVERTER INPUT SCREW TERMINALS 27 Re connect suction pressure transducer plug 28 Re connect EXV plug 20 Install inverter into control box Attach 12 mounting 29 Re connect high pressure switch plug screws 30 Re t i lve PEV plug 21 Re connect inverter ground lead Note wire color Green valve pus w Yellow Stripe 31 Re connect fan motor power harness plug 32 Re connect three compressor power wires Note wire color 22 Re t two input ires Note wi 1 der e connect two input power wires Note wire color order order Yellow Red and Black Black and Yellow 23 Re connect control wiring ABCD or thermostat 33 Replace the control box cover connections 34 Apply power to the unit 24 Re connect OAT OCT plug 25 Re connect discharge thermistor plug 26 COMPRESSOR REPLACEMENT Reference RCD Instruction 99TA516169 The following is a recommended procedure for compressor replacement Always refer to the unit product installation start up amp service instructions for deta
39. ange liquid line drier and suction filter Run a minimum of 2 or more hours and change liquid filter drier again Remove suction line filter from system do not replace suction line filter Use a test kit to determine whether acceptable acid and moisture levels have been attained If system is still contaminated repeat Step 22 Continue this process until the test kit indicates clean system Check system for normal operation If unit is a heat pump switch from heating to cooling a few times to verify component operation Recommended Filter Drier Sizes Minimum Required Unit Quantity Effective Desiccant Volume uanti Capaci EAS Liquid CU IN iur 2 3 4 5 1 6 5 15 29 WIRING DIAGRAMS CONNECTION DIAGRAM UNIT OPERATION w This control board contains a 3 5 minute short cycle protector A 3 5 minute delay will occur between pu EP Compressor offlon cycles To bypass delay short forced defrost pins for 1 second then release Ww However there is an additional 2 5 minutes delay upon expiration of the 3 5 minute short cycle delay to BLK ensure the high and
40. ant from the heat pump unit extended evacuation time may be required and or inadequate vacuum obtained The UI User Interface has provisions to open the EXV for refrigerant recovery and or evacuation 1 Connect gauges to 288BNV liquid and vapor service valve ports to monitor operating pressures during and at comple tion of the procedure Attach recovery system or vacuum pump to gauge set as needed for the service procedure The service valves must be open to evacuate the unit through the line set service ports The suction capillary service port is a direct connection to the suction port of the compressor and may also be used 2 In the advanced menu of the go to Checkout gt Heat Pump Evacuation 3 Set desired time period Default time period for the proced ure is 120 minutes 4 Select START on UI to open the valve 5 Begin evacuation or refrigerant recovery as required for the procedure after UI indicates the EXV is open Power may be removed from heat pump after the UI indicates READY TO EVACUATE 6 Remove power from indoor and heat pump unit prior to ser vicing unit The EXV will retain the open position NOTE See service training materials for troubleshooting the EXV using EXV CHECK mode Evacuation and recovery of refrigerant from 288BNV when using non communicating thermostat Refrigerant recovery and evacuation can be performed without a UI User Interface but will take more time If EXV is not force
41. appropriate fault code see Table 6 The control board should be replaced Brown Out Protection If the line voltage is less than 187V for at least 4 seconds the Compressor and OD fan goes to 0 rpm Compressor and fan operation are not allowed until voltage is a minimum of 190V The control will flash the appropriate fault code see Table 6 230V Line Power Disconnect Detection The control board senses the presence of absence of 230V through inverter feedback Voltage should present at all times when system is in service regardless if system is running or standby If there is no 230V at the inverter when the indoor unit is powered with a cooling or heating demand the appropriate fault code is displayed on UI communicating only see Table 6 If system is configured with conventional heat pump thermostat non communicating no fault code will be displayed on AOC board nor will any status LEDs be lit Use multimeter to check for the presence of 230V in this situation Pressure Switch Protection The outdoor unit is equipped with high pressure switch If the control senses the opening of a high pressure switch open 520 5 psig close 470 10 psig 77 it will respond as follows 1 Display the appropriate fault code see Table 6 2 After a 15 minute delay if there is a call for cooling or heat ing and HPS is reset the PEV opens for 150 seconds to equalize system pressures The compressor and fan w
42. ard for a 0 to 200 psig range of pressure at the suction tube This interpreted pressure data is then intelligently used by the AOC control board for low pressure cut out loss of charge management compressor protection oil circulation management lubrication management and EXV control Pressure Equalizer Valve PEV At the end of every compressor operation after the 3 5 minute Time Guard period the equalizer valve opens for 150 seconds plus an additional 15 seconds of protection before allowing the compressor to start ramping up The PEV is located next to the suction and discharge of the compressor The function of this valve is to prevent the compressor from starting with a high refrigerant pressure differential thus helping the reliability of the compressor NOTE A hissing sound may be heard during the equalization process This is normal Outdoor Coil Thermistor OCT The outdoor coil thermistor is a 10Kohm resistor used for multiple system operations It provides the coil liquid line temperature to the heat pump board and user interface Low ambient operation defrost initiation defrost termination and assistance with OAT temperature measurement of some of the functions see Fig 4 The sensor must be securely mounted to the tube connecting the and distributor See Fig 2 and Fig 3 for proper placement See Table 5 for proper resistances NUH Ef OCT Sensor Location
43. d open the recovery and evacuation must rely on check valve as a bypass 1 Connect gauges to 288BNV liquid and vapor service valve ports to monitor operating pressures during and at completion of the procedure Attach recovery system or vacuum pump to gauge set as needed for the service procedure The service valves must be open to evacuate the unit through the line set service ports The suction capillary service port is a direct connection to the suction port of the compressor and may also be used 2 Begin evacuation or refrigerant Allow extra time for refrigerant recovery and establishing a thorough evacuation Evacuation and recovery of refrigerant from 189BNV 1 Connect gauges to 189BNV liquid and vapor service valve ports to monitor operating pressures during and at comple tion of the procedure Attach recovery system or vacuum pump to gauge set as needed for the service procedure The service valves must be open to evacuate the unit through the line set service ports Evacuation and recovery of refrigerant from 189BNV when using non communicating thermostat 1 Connect gauges to 189BNV liquid and vapor service valve ports to monitor operating pressures during and at completion of the procedure Attach recovery system or vacuum pump to gauge set as needed for the service procedure The service valves must be open to evacuate the unit through the line set service ports Reversing Valve In heat pumps changeover between heating
44. d products could limit system life and void unit warranty 4 CAUTION 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 At the time of compressor change out and at regular preventative maintenance intervals the acid moisture content of the system should be checked using an acid moisture test kit This can determine in a few minutes whether acid and moisture are present in the system oil sample is required Contact your local distributor to purchase this device Before Changing the Compressor Check compressor and associated controls to be sure compressor replacement is necessary Failure Classification The replacement procedure is dependent on the type of failure The following describes the classification process MECHANICAL FAILURES ELECTRICAL BURNOUT 1s Ne Gamage to windings 1 Windings of compressor as indicated by electri 9 open or grounded cal check 2 Oil clean and odor free 2 Oil dark with burn odor 3 Symptoms Excessive 3 Symptoms Blows fuses or circuit breaker Draws ab normal amount of current Noise Won t Pump Excessively Hot Replacement Procedure for Mechanical Failure 1 Follow all safety warnings and notices 2 Precautions must be taken when servicing components within the control box of this unit
45. drier is used in cases where acid might occur such as burnout Heat pump units must have the drier installed between the compressor and accumulator only Remove after 10 hours of operation Never leave suction line filter drier in a system longer than 72 hours actual time Thermostatic Expansion Valve TXV All fan coils and furnace coils will have a factory installed thermostatic expansion valve TXV The TXV will be a bi flow hard shutoff with an external equalizer and a balance port pin A hard shut off TXV does not have a bleed port Therefore minimal equalization takes place after shutdown TXVs are specifically designed to operate with Puron or R 22 refrigerant use only factory authorized TXV s Do not interchange Puron and R 22 TXVs Operation The TXV is a metering device that is used in air conditioning and heat pump systems to adjust to changing load conditions by maintaining a preset superheat temperature at the outlet of the evaporator coil The volume of refrigerant metered through the valve seat is dependent upon the following 1 Superheat temperature is sensed by cap tube sensing bulb 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 push rods 2 The suction pressure at the outlet of the evaporator coil is transferred via the external equalizer tube to the underside of the dia
46. e or newer This combination will ensure achievement of comfort with the convenience of fingertip trouble shooting and diagnostic capability These units can also use a standard 2 stage or single stage thermostat for limited functionality ELECTRICAL 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Exercise extreme caution when working on any electrical components Shut off all power to system prior to troubleshooting Some troubleshooting techniques require power to remain on In these instances exercise extreme caution to avoid danger of electrical shock ONLY TRAINED SERVICE PERSONNEL SHOULD PERFORM ELECTRICAL TROUBLESHOOTING Aluminum Wire CAUTION UNIT OPERATION AND SAFETY HAZARD Failure to follow this caution may result in equipment damage or improper operation 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
47. emperature 10Kohm C F TEMPERATURE RESISTANCE ohms 25 0 77 0 10 0 2 3 0 0 32 0 32 6 3 2 28 0 18 4 85 5 3 4 50Kohm 125 0 257 0 1 7 1 6 75 0 167 0 7 40 2 0 25 0 77 0 50 0 2 3 THERMISTOR CURVE RESISTANCE KOHMS 0 20 40 60 80 100 120 TEMPERATURE DEG F A91431 Fig 18 10K Thermistor Resistance Versus Temperature 15 50K THERMISTOR A gt N ou RESISTANCE KOHMS N o o 0 20 40 60 80 100 120 TEMPERATURE F 14022 Fig 19 50K Thermistor Resistance Versus Temperature If the outdoor air or coil thermistor should fail the control will flash the appropriate fault code see Table 6 IMPORTANT The outdoor air thermistor coil thermistor and suction thermistor should be factory mounted in the final locations Check to ensure thermistors are mounted properly See Fig 2 3 4 5 and 6 Thermistor Sensor Comparison The control continuously monitors and compares the outdoor air temperature sensor and outdoor coil temperature sensor to ensure proper operating conditions The comparison is n cooling if the outdoor air sensor indicates gt 10 F gt 5 6 warmer than the coil sensor or
48. eration of compressor 91 Event INVERTER C OUT OVER 15 Min Both 92 baud VOLTAGE EVENT p Check that the service valves are fully open denly unloaded Inverter damage Replace inverter Occurs when bus volt 92 Event 15 Min Both age falls below 220 Check for interruption in main power supply VDC Occurs when incom System will try to ride through voltage spikes 93 Event 22086 PAPER VORASE 15 Min Both ing voltage is less than and self recover in trip condition persistent 197 VAC over current trips will lead to SM 96 Occurs when incom System will try to ride through voltage spikes 94 Event NA 15 Both ing voltage is more and self recover in trip condition persistent than 253 VAC over current trips will lead to SM 97 Compressor is operat ing outside the al lowed operational en Inverter will reduce speed to a lower stage velope Ad s Check refrigerant amount HIGH CURRENT LOCKOUT 5 System lockout occurs after repeated Outdoor Airflow too Check ODU coil fot clogging or debris and 95 2 Hours Both clean if necessary Troubleshoot ODU fan motor function 77 faults and lowest stage is low or off reached and make sure it is working Incoming power sup Check voltage versus unit rating plate for allow ply voltage able range Loose or incorrect wire Check incoming power leads and leads to the connections compressor plug Compressor internal Replace compressor damage Low supply line volt Check
49. f refrigerant from indoor coil and line set Pump Down Using 2 stg Tstat_ 189BNV Non Communicating Because this system has an inverter controlled compressor suction pressure transducer conventional procedure cannot be used to pump down and isolate the refrigerant into the outdoor unit 1 Connect gauges to 189BNV liquid and vapor service valve ports to monitor operating pressures during and at completion of the procedure 2 Force system to operate in high stage by creating a large differential between room temperature and set point on 33 thermostat Use multi meter to verify that 24 VAC is present between C and Y1 and Y2 terminals at outdoor unit 3 Close the liquid service valve 4 The unit will continue to run until high or low pressure switches open Close vapor service valve once compressor shuts down 5 Remove power from indoor and outdoor unit prior to servicing unit 6 A quantity of charge will remain in isolated section of system dependent on ambient temperature and overall system charge This charge must be manually recovered A recovery system will be required to remove final quantity of refrigerant from indoor coil and line set Evacuation and recovery of refrigerant from 288BNV Because this system has an EXV for the heating expansion device additional steps may be taken to open the EXV for fastest refrigerant recovery and evacuation If the EXV is not open when pulling a vacuum or recovering refriger
50. ference enclosed wiring diagrams and unit wiring diagrams in Owner s Manual to aid in reattaching electrical connections Reinstall control box cover INVERTER ASSEMBLY w SHIELD GASKET INSTALLATION Reference RCD Instruction 99TA512018 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Turn off the electrical supplies to the unit before performing any maintenance or service Follow the operating instructions on the label attached to the unit CAUTION ELECTRICAL OPERATION HAZARD Failure to follow this caution may result in unit damage or improper operation Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation IMPORTANT DO NOT USE POWER TOOLS TO TIGHTEN THE INVERTER INPUT SCREW TERMINALS Fan Motor Harness Plug Voltage Terminals Removing Inverter 25 1 Remove power to the unit Wait a minimum of two minutes before servicing the unit to allow inverter capacitors to discharge Follow safety instructions located on unit control box cover Precautions must be taken when servicing components within the control box of this unit The technician performing the service must determine that it is safe to work on or near the inverter The electrical disconnect that provides power to the unit must be turned off locked and tagged out This will insure that no damage will occur to
51. ghten or replace circuits Eletric Haale pius If User Interface is not requesting Electric Heat Heat Hee pump applica check for heater relays if on troubleshoot tion Electric Heater lectric Heater stuck on Heat If not in Defrost and Furnace is running same Furnace stuckcon time as heat pump troubleshoot Furnace Restriction in Filter Heat Drier plus Long Line Clean System refer to application guideline Application and filter and replace filter drier drier on Indoor Unit Heat Re Troubleshoot TXV Heat Troubleshoot EXV Service Valve left Heat closed Vapor Service Ensure Vapor Service Valve is open Valve Check Indoor for clogging ice or debris and clean or de ice if necessary Troubleshoot Heat Ingoor ae too low Indoor fan motor and make sure it is working follow Indoor Airflow troubleshooting instruc tion Check charge in cooling if in Cooling Charge Mode Ambient Range if low add charge us ing Charging Mode follow proper charging Heat Overcharged Syst m procedures if out side cooling charge mode range pull out charge weigh in using heating charge mode Heat a ims troubleshoot reversing valve Heat Restriction due to de Clean System refer to application guideline bris and replace filter drier 20 Table 7 Fault Code Actions continued Reset Flas
52. h Code Type AMBER LED DESCRIPTION Time Mode Possible Causes Actions System Mal FAN INVERTER TEMP LOCK Both See fault 62 Same actions for 62 85 OUT lockout occurs after 62 15 Min 7 function fault repeats 3X Both Inverter damage Replace inverter System Mal FAN INVERTER CURRENT Both See fault 63 Same actions for 63 86 functi LOCKOUT lockout occurs af 15 Min 7 unction ter 63 fault repeats 3X Both Inverter damage Replace inverter Both Blocked Inverter Heat Check Inverter fins for debris and clean if neces Exchanger fins sary Check Evaporator IDU in cooling ODU in heat Both Evaporator Airflow too ing for clogging ice or debris and clean if nec low or off essary Troubleshoot Evaporator fan motor and make sure it is working Check Condenser IDU in heating ODU in cool 88 System Mal ssi ioi TEMP 2H Both Condenser Airflow too ing for clogging ice or debris and clean if nec function lockou ine oe a ours low or off essary Troubleshoot Condenser fan motor and or 79 fault repeats 3X make sure it is working High Load conditions Both at cold ambient h at Over charge Check system charge ing or high ambient ge y 9 cooling Both Compressor damage Replace compressor Both Inverter damage Replace inverter Check compressor winding resistance mis 89 Sym Mal ANT LOCKOUT 15 Min Both Phase Imbalance wire of compressor leads at terminals U V W Inverter damage Replace inverter Occurs when bus volt Check op
53. il for clogging ice or debris and TEMP Temporary RPM re Outdoor Airflow too low or off clean if necessary Troubleshoot ODU fan motor and duction or stage lowering will make sure it is working 75 Event NA Both result Lockout occurs after Blocked Inverter Heat EX Check Inverter fins for debris and clean if necessary 75 fault repeats and stage can changer fins no longer be lowered Application violates guideline Consult Application Guideline for compliance 76 System Mal FAN INVERTER LOCKOUT 2 Hours Both If the fault repeats possible Replace inverter function repeated code 61 3X inverter damage Compressor is operating out side the allowed operational Inverter will reduce speed to a lower stage envelope MAXIMUM POWER MODE Incorrect refrigerant charge Check refrigerant amount CURRENT Temporary RPM Check ODU coil for clogging ice or debris and 7T Event reduction or stage lowering NA Both Outdoor Airflow too low or off clean if necessary Troubleshoot ODU fan motor and will result Lockout occurs af eS make sure it is working ter 7 7 fault repeats ud staga Incoming power supply volt Check voltage versus unit rating plate for allowable can no longer be lowered age range Loose or incorrect wire con Check incoming power leads and leads to the com nections pressor plug 79 Fault COMPRESSSS INVERTER 15 Min Both Compressor fails to start System will try to self mitigate with repeated start FAULT attempts System Mal SUCTION OVER
54. iled procedures A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Turn off and lock out all power to unit before proceeding Discharge all capacitors before proceeding wiring and electrical connections shall comply with all local and national electrical codes 4 WARNING PERSONAL INJURY HAZARD failure to follow this warning could result in personal injury Follow recognized safety practices and wear safety glasses protective clothing and gloves Acids formed as a result of motor burnout can cause burns 4 WARNING PERSONAL INJURY HAZARD failure to follow this warning could result in personal injury do not disassemble bolts plugs fittings etc until all pressure has been relieved from compressor 4 WARNING PERSONAL INJURY HAZARD failure to follow this warning could result in personal injury Do not operate compressor or provide any electrical power to the compressor unless the terminal box cover is in place and secured Measurements of amps and volts during running conditions must be taken at other points in the power supply Do not provide any power to the compressor unless suction and discharge service valves are open 4 CAUTION UNIT DAMAGE HAZARD failure to follow this caution may result in equipment damage or improper operation Only suction line filter driers should be used for refrigerant and oil clean up Use of non approve
55. ill then ramp to the next lower stage of operation until demand is satisfied In the next call for heating cooling system will re sume normal operation 3 If the opened switch closes at any time after the 15 minute delay then the PEV opens for 150 seconds to equalize sys tem pressures The compressor and fan will then ramp to the next lower stage of operation until demand is satisfied In the next call for heating cooling system will resume normal operation 4 If HPS trips 3 consecutive cycles the unit operation is locked out for 4 hours 5 In the event of a high pressure switch trip or high pressure lockout check the refrigerant charge outdoor fan operation and outdoor coil in cooling for airflow restrictions or in door airflow in heating 6 In the event of a low pressure trip or low pressure lockout check the refrigerant charge and indoor airflow cooling and outdoor fan operation and outdoor coil in heating Temperature Thermistors Thermistors are electronic devices which sense temperature As the temperature increases the resistance decreases 10Kohm thermistors are used to sense outdoor air temperature OAT coil temperature OCT and the suction line temperature OST located between the reversing valve and the accumulator 50Kohm thermistor is used to sense discharge temperature ODT Refer to Table 5 and Fig 18 and 19 for resistance values versus temperature Table 5 10K 50Kohm Resistance Values vs T
56. itching NOTE Compressor speed during defrost will go to defrost speed A14021 Fig 7 AOC Control Board CHECK CHARGE Charge in CHARGING mode communicating only Factory charge amount and desired subcooling are shown in the user interface UI To properly check or adjust charge conditions must be favorable for subcooling charging in cooling mode Favorable conditions exist when the outdoor temperature is between 65 F and 100 F 18 C and 38 C and the indoor temperature is between 70 F and 80 F 21 and 27 C If the temperatures are outside of these ranges weigh in charge only If charge confirmation is needed return to check subcooling in cooling mode when between 65 F 18 3 C and 100 F 37 8 C or use heating check chart in heating mode below 65 F 18 3 C Charging Procedure Unit is factory charged for 15ft 4 57 m of lineset If any refrigerant charge adjustment is required due to the user inputted line set length the UI will calculate and display the target subcooling and the amount of additional charge to be added Therefore the UI is your source of information for charging the system correctly Refrigerant charge adjustment amount for adding or removing 0 6 oz ft 17 74 g m of 3 8 liquid line above or below 15ft 4 57 m respectively Perform a final charge check only when in cooling and OD is between 65 F 18 C and 100 F 38 C NOTE Ul indicates acceptable conditions if outside of this range
57. l plug Re install original del pl on service board e install original model plug con Replace AOC control 15 Min System will self mitigate by reducing the then re stage persistent conditions will lead to lock 31 BR SURE SWITCH duced Both High Pressure Event out refer to Error Code 84 2 hours of accu OPEN stage op mulated operation without further fault will eration reset fault counter System will self mitigate persistent condi tions will lead to lockout refer to Error Code 32 Event LOW PRESSURE TRIP 15 Min Both Low Pressure Event 83 2 hours of accumulated operation without further fault will reset fault counter System Damaged AOC con 45 bin ction CONTROL FAULT NA Both 9 trol Power cycle Replace control 46 Event BROWNOUT EVENT 6 Min Both low line voltages if persistent contact power provider Or gonna Verify good harness connection m System LOST INVERTER COMMUNI ii Boh ed harness yg Malfunction CATIONS ot Possible damage to VSD change out the Inverter drive Eod en if persistent contact power provider 230VAC DROPOUT RESET 49 Fault EVENT 6 Min Both Damaged Inverter Change out ODU control before Inverter Drive if this does not help then change out rive the Inverter drive Sensor Harness not connected to AOC Ensure plug is connected to AOC control control Broken or loose har Check harness for continuity resistance 52 Fault SEN N
58. le 6 for other delay information COMMUNICATION AND STATUS FUNCTION LIGHTS Evolution Connex Control Green Communications COMM Light A green LED COMM light on the outdoor board see Fig 7 indicates successful communication with the other system products The green LED will remain OFF until communication is established Once a valid command is received the green LED will turn ON continuously If no communication is received within 2 minutes the LED will be turned OFF until the next valid communication The green LED will be turned off when using a standard 2 stage non communicating heat pump thermostat Amber Status Light Amber colored STATUS light indicates operation and error status See Table 6 for definitions Two minute time delay to return to standby operation from last valid communication Defrost This user interface UI offers 5 possible defrost interval times 30 60 and 90 minutes or AUTO The default is AUTO Defrost interval times 30 60 and 90 minutes or AUTO are selected by the Evolution Connex Control User Interface if using UI The 90 and 120 minute selection will default to 60 minutes at ambient below 37 degrees The 120 minute selection will default to 90 minutes at ambient above 37 degrees If using non communicating thermostat defrost intervals are set using dip switches on outdoor control board see Fig 7 AUTO defrosts adjusts the defrost interval time based on the last defrost time as follows
59. lowed Pump Down Evolution Communicating 288BNV Because this system is inverter controlled compressor suction pressure transducer and EXV conventional procedure cannot be used to pump down isolate the refrigerant into the outdoor unit The UI User Interface has provisions to assist in performing this function 1 Connect gauges to 288BNV liquid and vapor service valve ports to monitor operating pressures during and at comple tion of the procedure 2 In the advanced menu of the go to Checkout gt Heat Pump Pumpdown 3 Select mode to pump down in COOL or HEAT COOL mode allows refrigerant to be isolated in outdoor unit HEAT mode allows the refrigerant to be isolated in indoor coil and lineset Set desired time period Default time peri od for the procedure is 120 minutes 4 Select Start on UI to begin the pump down process Unit will begin running in selected mode after a brief delay 5 Close the liquid service valve 6 The unit will run in selected mode with the low pressure protection set to indicate pump down is complete when the suction pressure drops below 10 psig Compressor protec tions are still active to prevent damage to the compressor or inverter high pressure high current high torque etc 7 Once system indicates pump down complete or failure to complete shutdown close vapor service valve 8 A small quantity of charge will remain in isolated section of system dependent on a
60. m 55 Fault COIL TEMP SENSOR FAULT NA Both es Ensure Sensor is properly clipped to the dis properly attached or i tributor entry tube in wrong location Broken or Damaged Check harness for continuity resistance Sensor should be 10 kOhm Hardware damage to control Replace AOC control Coil Thermistor not Ensure Sensor is properly clipped to the dis properly attached of tributor entry tube in wrong location Outdoor Ambient 56 Event OAT SUr a NA Both Temperature sensor improperly R hag Properly install OAT sensor sensor body may be pery in contact with sheet metal Sensor Harness not connected to AOC Ensure plug is connected to AOC control control Broken or loose har rese wire Check harness SUCTION PRESSURE SEN Compare transducer reading to gauge read of Fault SOR FAULT 19Min Both m de ing at service valve see transducer measure d NOU uger ment chart Check system for electrical es Ice shorts and correct replace transducer gt Compare transducer reading to gauge read Heat En during ing at service valve see transducer measure 9 ment chart replace transducer Suction Thermistor f not properly attached ue plug is properly attached to suction SUCTION THERMISTOR OUI WO location 58 Fault RANGE FAULT NA Both Broken or loose har Check harness for continuity resistance ness wire should be 10 kOhm Outdoor Air Thermis tor Issue See Error 53 and or Error 56 Both Indoor
61. mbient temperature and overall sys tem charge This charge must be manually recovered A recovery system will be required to remove final quantity of refrigerant from indoor coil and line set 9 Remove power from indoor and heat pump unit prior to ser vicing unit Pump Down Evolution Communicating 1898 Because this system is inverter controlled compressor suction pressure transducer conventional procedure cannot be used to pump down and isolate the refrigerant into the outdoor unit The UI User Interface has provisions to assist in performing this function 1 Connect gauges to 189BNV liquid and vapor service valve ports to monitor operating pressures during and at comple tion of the procedure 2 In the advanced menu of the UI go to Checkout Pump down 3 Select mode to pump down in COOL Set desired time period Default time period for the procedure is 120 min utes 4 Select Start on UI to begin the pump down process Unit will begin running in selected mode after a brief delay 5 Close the liquid service valve 6 The unit will run in selected mode with the low pressure protection set to indicate pump down is complete when the suction pressure drops below 10 psig Compressor protec tions are still active to prevent damage to the compressor or inverter high pressure high current high torque etc 7 Once system indicates pump down complete or failure to complete shutdown close vapor service
62. move control box cover for 2 minutes after power has been removed from unit PRIOR TO TOUCHING ELECTRICAL COMPONENTS Verify zero 0 voltage at inverter connections shown on inverter cover a WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label A WARNING EXPLOSION HAZARD Failure to follow this warning could result in death serious personal injury and or property damage Never use air or gases containing oxygen for leak testing or operating refrigerant compressors Pressurized mixtures of air or gases containing oxygen can lead to an explosion A WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury or equipment damage Puron R 410A systems operate at higher pressures than standard R 22 systems Do not use R 22 service equipment or components on Puron equipment Ensure service equipment is rated for Puron 4 CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing and gloves when handling parts Refrigeration systems contain refrigerant under
63. new one provided do not fasten at this time Note how the compressor harness is routed to suction tube Highlighted in yellow below 23 9 With using a slot screwdriver lift up the on the side tab to pry the cover off from the RTV Be sure not to break the tab W 10 It may be necessary to leverage the screwdriver against cover next to tab so as not to break the tab while loosening 11 Once Cover is loosened on one side use screwdriver along freed edge to remove 17 18 24 12 13 14 15 16 Remove cover unplug old harness plug in new harness verify bushing is reinstalled and plug leads leave the terminal box through the bushing reinstall cover pushing one side down then the other NOTE DO NOT SCRAP SEALANT Reinstall compressor sound blanket making sure discharge thermistor and compressor power harness are routed as they were from the factory Route compressor power harness to new double loop wire tie and then to the wire retainers in tube sheet route as they were originally to make sure they will not contact fan blade and then route into control box and reinstall two control box screws See image below SN ANZ Reinstall service panel Route compressor harness choke to left hand side of the top of control box and push in wire tie Pull wires tight as they enter control box and tighten second wire tie Reconnect compressor power harness to the inverter NOTE Re
64. ng compressor harness replace with new one provided do not fasten at this time Note how the compressor harness is routed to suction tube highlighted in yellow below 10 11 12 13 14 15 16 17 18 19 28 Remove compressor mounting hardware Cut both suction and discharge lines with tubing cutter Do not use brazing torch for compressor removal as oil vapor may ignite when compressor is disconnected Using caution and the appropriate lifting devices remove compressor from the unit Scratch matching marks on stubs in old compressor Make corresponding marks on replacement compressor Use torch to remove stubs from old compressor and install them in replacement compressor NOTE Use appropriate protection to avoid damage to compressor terminal cover and or terminal box sealant with torch flame It is intended that terminal cover remain installed during compressor installation Using caution and the appropriate lifting device place replacement compressor in unit and secure with appropriate mounting hardware NOTE Use of existing or new OEM mounting hardware is recommended NOTE Compressor grommet and sleeve supplied with the compressor should be evaluated versus OEM hardware before assembling in unit Use copper couplings to tie compressor back into system NOTE Use appropriate protection to avoid damage to compressor terminal cover and or terminal box sealant with torch flame It is in
65. ng a few times to verify component operation Replacement Procedure for Electrical Burnout System Clean up Mild Burnout Perform steps 1 25 as specified in the Replacement Procedure for Mechanical Failure and then perform steps as follows 26 27 28 Run unit a minimum of 2 hours and replace liquid line filter drier Use a test kit to determine whether acceptable acid and moisture levels have been attained If system is still contaminated repeat step 17 Continue this process until the test kit indicates clean system Check system for normal operation If unit is a heat pump switch from heating to cooling a few times to verify component operation Severe Burnout Perform steps 1 22 as specified in the Replacement Procedure for Mechanical Failure and then perform steps as follows 23 24 25 26 27 28 29 30 31 Clean or replace TXV Drain any trapped oil from the accumulator if used Add suction line filter drier for appropriate unit size as indicated Recommended Filter Drier Sizes table below Mount vertical with pressure taps on both inlet and outlet NOTE On heat pumps install suction line drier between compressor and accumulator Triple evacuate the system below 1 000 microns Recharge unit compensating for larger liquid line filter Charge compensation for oversize filter drier is listed in Recommended Filter Drier Sizes table below Run 1 hour minimum and ch
66. ng the second digit of the error code The short flash is 0 25 seconds ON and the long flash is 1 0 second ON Time between flashes is 0 25 seconds Time between short flash and first long flash is 1 0 second Time between code repeating is 2 5 seconds with LED OFF Codes are easily read from user interface UI EXAMPLE 3 short flashes followed by 2 long flashes indicates a 32 code Table 6 shows this to be low pressure switch open Variable Speed Compressor Winding Resistance This compressor operates with 3 phase variable frequency PWM variable voltage For troubleshooting certain fault codes related to compressor resistances follow these steps 1 Disconnect compressor power leads from the inverter MOC terminals U YEL V RED and W BLK 2 Measure the resistance between YEL to RED YEL to BLK and RED to BLK and compare to Table 4 values Each resistance set should be equal 3 Measure the resistance to ground for each lead 4 If the resistances check out reconnect power leads to appropriate terminal 5 If the resistances appear to be abnormal it will be necessary to measure the resistance at the compressor fusite terminals 6 During the removal of the compressor fusite cap do not re move the RTV sealant Remove the harness plug measure the resistances and compare to Table 4 7 Special care will need to be taken with the replacement of the compressor fusite cap Make sure the two holes in the compressor f
67. 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 Unit Electrical Power Power wires from the unit s disconnect should be routed through the power wiring hole provided at the bottom of the unit s control box Connect the ground wire to the ground connection in the control box and connect the power wiring to the terminal block as shown on the wiring and Installation Instructions supplied with the unit The unit does not require a contactor or outdoor unit transformer in order to operate MAJOR COMPONENTS Application Operational Control Board AOC 13361 Fig 1 AOC Application Operational Control Board The AOC board is located in the lower right hand side of inverter tray It
68. ome plugged Some oil is contained in refrigerant returning to compressor It cannot boil off in accumulator with liquid refrigerant The bleed hole allows a small amount of oil and refrigerant to enter the return line where velocity of refrigerant returns it to compressor If bleed hole plugs oil is trapped in accumulator and compressor will eventually fail from lack of lubrication If bleed hole is plugged accumulator must be changed The accumulator has a fusible element located in the bottom end bell See Fig 24 This fusible element will melt at 430 221 and vent the refrigerant if this temperature is reached either internal or external to the system If fuse melts the accumulator must be replaced im 430 FUSE ELEMENT A88410 Fig 24 Accumulator 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 A CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant 4 Remove accumulator from system with tubing cutter 5 Tape ends of open tubing 6 Scratch matching marks on tubing studs and old accumulator Scratch matching marks on new accumulator Unbraze stubs from old accumulato
69. oot TXV see guide below replace if necessary Heat Troubleshoot EXV see guide below Outside Normal Operating Range e g improper load Heat calculation system match is Consult Application Guidelines Sue outside heating range etc Heat Service Valve loft closed Liq Ensure Liquid Service Valve is open uid Service Valve Check Outdoor for clogging ice or debris and Heat Outdoor Airflow too low or off clean or de ice if necessary Troubleshoot Outdoor fan motor and make sure it is working follow Out door Airflow troubleshooting instruction Check charge in cooling if in Cooling Charge Mode Ambient Range if low add charge using Charging Heat Undercharged System Mode follow proper charging procedures if out side cooling charge mode range pull out charge weigh in using heating charge mode Heat Reversing Valve Bypass Reversing Valve Stuck halfway troubleshoot revers ing valve Heat Restriction due to debris Clean System refer to application guideline and replace filter drier 19 Table 7 Fault Code Actions continued Reset Flash Code Type AMBER LED DESCRIPTION Time Mode Possible Causes Actions Outside Normal Oper ating Range e g im proper load calcula Both tion system match is Consult Application Guidelines Sue outside cooling range outside heat ing range etc Both loops Pressure Check HPS harne
70. operation The compressor in a Puron system uses a Polyol Ester POE oil This oil is extremely hygroscopic meaning it absorbs water readily POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of the oil to the atmosphere Servicing Systems on Roofs With Synthetic Materials POE Polyol Ester compressor lubricants are known to cause long term damage to some synthetic roofing materials Exposure even if immediately cleaned up may cause embrittlement leading to cracking to occur in one year or more When performing any service which may risk exposure of compressor oil to the roof take appropriate precautions to protect roofing Procedures which risk oil leakage include but are not limited to compressor replacement repairing refrigerants leaks replacing refrigerant components such as filter drier pressure switch metering device coil accumulator or reversing valve Synthetic Roof Precautionary Procedure 1 Cover extended roof working area with an impermeable polyethylene plastic drop cloth or tarp Cover an approximate 10 x 10 ft area 2 Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run offs and protect drop cloth from tears caused by tools or components 3 Place terry cloth shop towel inside unit immediately under component s to be serviced and prevent
71. or death INJURY AND UNIT DAMAGE Due to the high pressure of nitrogen it should never be used without a pressure regulator on the tank Assuming that a system is pressurized with either all refrigerant or a mixture of nitrogen and refrigerant leaks in the system can be found with an electronic leak detector that is capable of detecting specific refrigerants If system has been operating for some time first check for a leak 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 A simple and inexpensive method of testing for leaks is to use soap bubbles See Fig 26 Any solution of water and soap may be used Soap solution is applied to all joints and connections in system A small pinhole leak is located by tracing bubbles in soap solution around leak If the leak is very small several minutes may pass before a bubble will form Popular commercial leak detection solutions give better longer lasting bubbles and more accurate results than plain soapy water The bubble solution must be removed from the tubing and fittings after checking for leaks as some solutions may corrode the metal 36 LEAK DETECTOR SOLUTION A95423 Fig 26 Bubble Leak Detection You may use an electronic leak detector designed for specific refrigerant to check for leaks See Fig 25 This unquestionably is the most efficient and easiest
72. ors since sit eee TIT 15 Control Fault prt v ERE ege Re Be dares Ring 15 Brown Out Protection bcc voc once enter aede Helse aE edad b ace gei ATE Tee gee Gel eed ees 15 230v Line Power Disconnect Detection 15 Pressure Switch Protectioti 3 3120 ar I Cheese PER ER 15 Temperature EhermistoIS cies eese iege ie ce gU Eos UE De quce EU UR 15 Fault Code Action Table cinese ache ee ace RR PR ace e eR OP RR b CAR Rp eR aa 17 Variable Speed Drive LED Location and Description 2 22 Compressor Power Harness Assembly Replacement 23 Inverter Assembly with Shield Gasket Installation 1 1 1 2 1 25 Compressor Replacement 4 2 Ce Rete REG n EG Re denso Ride p dors 27 WIRING DIAGRAMS OPI ELE Ve bre rede hee ed nei veda e ete 30 31 REFRIGERATION SYSTEM sic as ss x sone seca tenes EER EERS VETE a ERES IR RE EE EE R 32 36 Retrigeratt etos eb er eoe aceto bete datae a ated ace ea PE
73. phragm This is needed to account for the indoor coil pressure drop Residential coils typically have a high pressure drop which requires this valve feature 3 The pin is spring loaded which exerts pressure on the underside of the diaphragm Therefore the bulb pressure works against the spring pressure and evaporator suction pressure to open the valve If the load increases the temperature increases at the bulb which increases the pressure on the top side of the diaphragm This opens the valve and increases the flow of refrigerant The increased refrigerant flow causes the leaving evaporator temperature to decrease This lowers the pressure on the diaphragm and closes the pin The refrigerant flow is effectively stabilized to the load demand with negligible change in superheat 35 Accumulator The accumulator is specifically designed to operate with Puron or R22 respectfully use only factory authorized components Under some light load conditions on indoor coils liquid refrigerant 15 present in suction gas returning to compressor The accumulator stores liquid and allows it to boil off into a vapor so it can be safely returned to compressor Since a compressor is designed to pump refrigerant in its gaseous state introduction of liquid into it could cause severe damage or total failure of compressor The accumulator is a passive device which seldom needs replacing Occasionally its internal oil return orifice or bleed hole may bec
74. r and braze into new accumulator 7 Thoroughly rinse any flux residue from joints and paint with corrosion resistant coating such as zinc rich paint 8 Install factory authorized accumulator into system with copper slip couplings 9 Evacuate and charge system Pour and measure oil quantity if any from old accumulator If more than 20 percent of oil charge is trapped in accumulator add new POE oil to compressor to make up for this loss 4A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label REFRIGERATION SYSTEM REPAIR Leak Detection New installations should be checked for leaks prior to complete charging If a system has lost all or most of its charge system must be pressurized again to approximately 150 psi minimum and 375 psi maximum This can be done by adding refrigerant using normal charging procedures or by pressurizing system with nitrogen less expensive than refrigerant Nitrogen also leaks faster than refrigerants Nitrogen cannot however be detected by an electronic leak detector See Fig 25 A95422 Fig 25 Electronic Leak Detection 4 WARNING PERSONAL HAZARD Failure to follow this warning could result in personal injury
75. re to follow this warning could result in personal injury or equipment damage Cut tubing to reduce possibility of personal injury and fire 8 Use midget tubing cutter to cut liquid and vapor lines at both sides of coil Cut in convenient location for easy reassembly with copper slip couplings 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 37 Copyright 2014 Bryant Heating amp Cooling System 7310 W Morris St e Indianapolis 46231 Edition Date 07 14 Catalog No SM288BNV 189BNV 01 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces NEW 38
76. ription Communications Loss Loss of communication with outdoor unit AOC board 179 AOC board should be replaced Control Fault Internal Board Failure 45 AOC board has failed AOC board should be replaced NOTE If any of the AOC control board header pins are damaged or are not making good contact AOC board should be replaced 22 COMPRESSOR POWER HARNESS ASSEMBLY REPLACEMENT Reference RCD Instruction 99TA516170 The following is a recommended procedure for compressor power harness replacement Always refer to the unit product installation start up amp service instructions for detailed procedures A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Turn off and lock out all power to unit before proceeding Discharge all capacitors before proceeding wiring and electrical connections shall comply with all local and national electrical codes 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death failure to follow this warning could result in personal injury Do not operate compressor or provide any electrical power to the compressor unless the terminal box cover is in place and secured Measurements of amps and volts during running conditions must be taken at other points in the power supply Do not provide any power to the compressor unless suction and discharge
77. s functions include Compressor speed control Outdoor fan motor control Reversing valve operation Defrost operation Crankcase heater operation Pressure switch monitoring Time Delays Pressure Transducer measurements PEV control pressure equalizer valve Temperature measurements EXV Electronic Expansion Valve operation control nverter communication and control Inverter The inverter is located inside the control box This is an air cooled device that communicates with the control board and drives the compressor and fan motor to the demanded RPM The inverter is always powered with line voltage since no contactor is used The inverter changes the line voltage to DC volts and then recreates 3 phase sine waves that vary in frequency to drive the compressor and fan motor at the desired RPM NOTE The unit may be operated with an Evolution Connex Control or a standard 2 stage HP thermostat Evolution Connex Control will utilize 5 stages of heating and cooling while 2 stage HP thermostat will only allow 2 discrete stages of heating and cooling operation Variable Speed Compressor This unit contains a variable speed rotary compressor that has a wide operating range It operates on a variable 3 phase sine wave provided by the inverter This compressor can only be operated by the specific inverter supplied with the unit CAUTION EQUIPMENT DAMAGE HAZARD Failure to follow this caution may res
78. solenoid coil from valve body Remove valve by cutting it from system with tubing cutter Repair person should cut in such a way that stubs can be easily re brazed back into system Do not use hacksaw This introduces chips into system that cause failure After defective valve is removed wrap it in wet rag and carefully unbraze stubs Save stubs for future use Because defective valve is not overheated it can be analyzed for cause of failure when it is returned 3 Braze new valve onto used stubs Keep stubs oriented correctly Scratch corresponding matching marks on old valve and stubs and on new valve body to aid in lining up new valve properly When brazing stubs into valve protect valve body with wet rag to prevent overheating 4 Use slip couplings to install new valve with stubs back into system Even if stubs are long wrap valve with a wet rag to prevent overheating 5 After valve is brazed in check for leaks Evacuate and charge system Operate system in both modes several times to be sure valve functions properly 34 FROM INDOOR COIL VIA TO OUTDOOR SERVICE VALVE ON COIL OUTDOOR COIL TO ACCUMULATOR FROM COMPRESSOR DISCHARGE LINE A88342 Fig 22 Reversing Valve Cooling Mode or Defrost Mode Solenoid Energized TO INDOOR COIL VIA SERVICE VALVE ON OUTDOOR COIL TO FROM A MULATOR OUTDOOR CCUMULATO COIL 4 INSULATE FOR ACCURATE ON READING INSULATE FOR TP 3 e ACCURATE READING
79. ss Switch harness leads Pressure Switch dis Both connected from ODU Check HPS connection on ODU control Control Board Check Discharge pressure with gauge if less Both Faulty Pressure than 610 20 psig and switch is open Switch measure resistance then replace pressure Switch Restriction due to de Both bris leading to Over Clean System refer to application guideline charge when charg and replace filter drier ing in Cooling mode Restriction in EXV plus Long Line Appli Both Da Musis If long line troubleshoot EXV charging in Cooling mode Both None condensable Clean System refer to application guideline leading to high load and replace filter drier Service Valve left Cool closed Liquid or Va Ensure Service Valves are open por Check system charge using Cooling Charging Coo Overcharged System Mode follow proper charging procedures Check Outdoor Coil for clogging ice or de 3 bris and clean de ice if necessary Trou peli too Outdoor fan motor make sure it OW orp is working follow Outdoor Airflow trou HIGH PRESSURE LOCKOUT bleshooting instruction System 4 HOURS lockout occurs af Restriction in Filter 84 Malfunction ter 31 fault repeats 3X and 4 Hours Drier plus Long Line Clean System refer to application guideline stage can no longer be low Cool Application and filter and replace filter drier ered drier on Outdoor Unit Cool d i Eh ice troubleshoot EXV Check kinks strai
80. ssor reliability Itis a delay that cannot and must not be bypassed The internal crankcase heater is energized during off cycle as needed DEFROST TIME SELECTION The Defrost Interval Time Can Be Field Selected Dependent Upon Local Georgraphic Requirements It Is Factory Set At 90 Minutes And Can Be Changed To Either 30 60 Or 120 Minutes Via The User Interface or Dip Switches However if changed at outdoor temperature less than 37 F the Defrost Interval will be 60 minute maximum unless 30 minute is selected User Interface Defaults to AUTO DEFROST Defrost Will Only Be Performed At Outdoor Temperatures Less Than 50 F Defrost Wil Initiate When Time Selected Has Elapsed And The Coil Temperature Is Less Than 32 F 2 F Terminate At 65 F 50 F or 45 F 5 F As Needed Based On OAT At Defrost Termination The Outdoor Fan Will Turn On 15 Seconds Before Switching The Reversing Valve FIELD INITIATED FORCED DEFROST Shown As Forced Defrost On Board By Placing A Jumper Across The Forced Defrost Terminals For 5 Seconds Or Longer And Then Removing The Jumper The Unit Will Initate A Defrost Cycle Regardless Of Coil Temperature The Defrost Cycle Will Terminate At 65 F 5 F If Coil Termperature Is Above 32 F Or Outdoor Ambient Temperature Is Above 50 F Defrost Mode Will Terminate After 30 Seconds Of Active Mode NOTES 1 To Be Wired In Accordance With National Electric Code N E C And Local Codes 2 Use Copper
81. tch Open Low Pressure Trip Control Fault Brownout Event Lost Inverter Communication 230VAC Dropout Reset Event Outdoor Discharge Temp Sensor Fault Outdoor Air Temp Sensor Fault Suction Temp Sensor Fault Coil Temp Sensor Fault OAT OCT Thermistor Out of Range Suction Pressure Sensor Fault SuctionThermistor Range Fault Discharge Temperature Out of RangeEvent Fan Inverter Fault Fan Inverter Temp High Fan Inverter Over Current D C Voltage Low Fault Outdoor Fan Dropped Out Stator Heater Fault Inverter Compressor Internal Fault Compressor Dropped Out Suction Over Temperature Event Discharge Temp Out of Range Lockout Maximum Power Mode Temp Fan Inverter Lockout Maximum Power Mode Comp Current Compressor Inverter Fault Suction Over Temp Lockout Low Pressure Lockout for 4 hours High Pressure Lockout for 4 hours Fan Inverter Temp Lockout Fan Inverter Current Lockout nverter Temp Lockout Compressor Inverter Overcurrent Lockout nverter VDC Out Over Voltage Event nverter VDC Out Under Voltage Event 230VAC Under Voltage Event 230VAC Over Voltage Event High Current Lockout VDC Under Voltage Lockout VDC Over Voltage Lockout High Torque Event High Torque Lockout o es 52 56 59 eo co co oo oco D gt Oy lAN oc OW Po 14 TT co 91 92
82. tdoor Ambient Temperature F Fig 14 Heating Pressure Check Chart 288BNV24 25 Refrigerant Pressure psig Heating Check Chart 36 4 For use in Heating Charging Mode only For all AHRI listed indoor combinations Vapor Service Valve Pressure 50 1 pn 10 Outdoor Ambient Temperature F C f Fo 3102 2757 2413 2068 1724 1380 1034 690 345 Refrigerant Pressure KPa Fig 15 Heating Pressure Check Chart 288BNV36 Refrigerant Pressure psig Heating Check Chart 48 For use in Heating Charging Mode only Outdoor Ambient Temperature F C 3102 2757 2413 2068 1724 1380 1034 690 345 Refrigerant Pressure KPa Fig 16 Heating Pressure Check Chart 288BNV48 13 TROUBLESHOOTING Service Tool Connect to 120VAC to 24vac 0 5A min adapter A14178 Fig 17 Service Tool Connection When working on the outdoor unit of a split system the technician would usually need to repeatedly walk between the indoor wall control and the unit outside To save time the communicating controls offer a service tool feature By wiring the service tool into the AOC board and powering it with an external adapter the technician can have a wall control capable of running the system right at the outdoor unit To use a service tool connect the A and B communication bus wires from this second communicating control
83. tection against over temperature of the compressor The ODT is located on the compressor discharge stub out see Fig 6 A14024 Fig 6 Discharge Thermistor ODT Crankcase Heater Operation This unit has an internal crankcase heater that will be energized during the off cycle and is intelligently demanded by the system to prevent the compressor from being the coldest part of the system thus enhancing the reliability The crankcase heater will function as needed any time the outdoor unit is powered The indoor unit and UI do not need to be installed for the crankcase heater to operate properly The compressor windings will occasionally be energized during the OFF cycle depending on the length of the OFF cycle to start the stator heat operation thus maintaining a sump temperature that is essential for compressor reliability The compressor will not run during this process Time Delays The unit time delays include 3 5 minute time delay after last cycle initial power up return from brown out condition To bypass this feature momentarily short and release Forced Defrost pins At the end of every compressor ON cycle there will be 150 seconds of PEV open period for pressure equalization followed by 15 seconds of PEV Off period before the next compressor ON cycle This delay cannot be bypassed as it helps compressor reliability 15 second delay at termination of defrost before the auxiliary heat is de energized See Tab
84. tended that terminal cover remain installed during compressor installation Remove and discard liquid line strainer and filter drier Replace with filter drier one size larger in capacity than the unit being worked on use bi flow type on heat pump See Recommended Filter Drier Sizes table below for appropriate size Reinstall compressor sound blanket making sure discharge thermistor and compressor power harness are routed as they were from the factory Route compressor power harness to new double loop wire tie and then to the wire retainers in tube sheet route as they were originally to make sure they will not contact fan blade and then route into control box and reinstall two control box screws See image below N CN 20 21 22 23 24 25 Reinstall service panel Route compressor harness choke to left hand side of the top of control box and push in wire tie Pull wires tight as they enter control box and tighten second wire tie Reconnect compressor power harness to the inverter NOTE Reference enclosed wiring diagrams and unit wiring diagrams in Owner s Manual to aid in reattaching electrical connections Triple evacuate the system below 1 000 microns Recharge unit compensating for larger liquid line filter Charge compensation for oversize filter drier is listed in the Recommended Filter Drier Sizes table below Check system for normal operation If unit is a heat pump switch from heating to cooli
85. to the unit use a metal barrier between brazing area and unit After the brazing operation and the refrigerant tubing and 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 32 The service valve stem cap is tightened to 20 2 ft Ib torque and the service port caps to 9 2 ft lb torque The seating surface of the valve stem has a knife set edge against which the caps are tightened to attain a metal to metal seal The service valve cannot be field repaired therefore only a complete valve or valve stem and service port caps are available for replacement If the service valve is to be replaced a metal barrier must be inserted between the valve and the unit to prevent damaging the unit exterior from the heat of the brazing operations CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant Pumpdown amp Evacuation 4 CAUTION ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental damage Federal regulations require that you do not vent refrigerant to the atmosphere Recover during system repair or final unit disposal If this system requires either a Pump Down or Evacuation for any reason the procedures below must be fol
86. ult in equipment damage and or improper operation Do not attempt to apply line voltage directly to the compressor This will destroy the compressor Electronic Expansion Valve EXV This unit uses an electronic expansion valve for refrigerant metering in the heating mode The control board drives the EXV to its proper position based on the operating mode and conditions The Evolution Connex Control Service mode allows for manual opening and closing of the EXV for troubleshooting and pump down Outdoor Fan Motor The compact ECM outdoor fan motor is a variable speed brushless DC BLDC motor that operates at speeds from 500 to 1050 RPM The motor is a 3 phase permanent magnet type motor Just like the compressor this motor speed is determined by the inverter output frequency and amplitude Motor speed is controlled through the inverter board in the outdoor unit and no electronic module is attached Motor speed is slowed as the building load decreases maintaining the proper condensing temperature for both cooling and dehumidification As the building load increases the motor will increase speed until it is at maximum speed at the maximum building load At unit start up there is a slight delay and thrust motion of the fan motor blade in the reverse direction prior to ramping up the fan assembly Pressure Transducer SPT A 5 VDC output low pressure transducer that provides a 0 5 VDC data for interpretation by the control bo
87. unit ize w 0 20 21 30 31 40 41 50 51 60 61 70 71 80 0 6 1 6 4 9 1 9 4 12 2 12 5 15 2 15 5 18 3 18 6 21 3 21 6 24 4 2 Ton 3 8 100 100 100 100 100 100 100 3 Ton 3 8 100 100 100 100 100 100 100 4 3 8 100 100 100 100 100 100 Maximum actual length not to exceed 100 ft 30 5 m T Total equivalent length accounts for losses due to elbows or fitting outside acceptable range LONG LINE APPLICATIONS Unit is approved for up to 100 ft 30 5 m equivalent length and vertical separations shown above with no additional accessories Longer line set applications are not permitted SAFETY CONSIDERATIONS Installation service and repair of these units should be attempted only by trained service technicians familiar with standard service instruction and training material equipment should be installed in accordance with accepted practices and unit Installation Instructions and in compliance with all national and local codes Power should be turned off when servicing or repairing electrical components Extreme caution should be observed when troubleshooting electrical components with power on Observe all warning notices posted on equipment and in instructions or manuals WARNING ELECTRICAL HAZARD HIGH VOLTAGE Failure to follow this warning could result in personal injury or death Electrical components may hold charge DO NOT re
88. usite terminal box are still full of RTV sealant before the cap is reinstalled The factory RTV can be reused as long as none of it has been removed during the cap removal 8 Reinstall compressor sound blanket making sure discharge thermistor and compressor power harness are routed as they were from the factory 14 Table 4 Variable Speed Compressor Resistance winding resistance at 70 F 20 F WINDING MODEL 288BNV 024 025 036 048 0 59 0 59 0 59 0 37 Between terminals OHM OHM OHM OHM Between terminal amp ground gt 1 mega OHM CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage and or improper operation Do not use Meggar for measuring the winding resistance 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage and or improper operation To maintain water integrity of the compressor fusite terminal box the two holes in outer ring need to be full of RTV sealant Fan Motor If verification of proper operation is required for the fan motor used in this unit follow these steps 1 Disconnect fan motor connector from control board 2 Measure resistance between any 2 of the 3 leads present 3 Compare measurement to values below Fan Motor Resistance Unit Size Resistance Ohms 024 025 036 048 11 1 Control Fault If the outdoor unit control board has failed the control will flash the
89. valve 8 A small quantity of charge will remain in isolated section of system dependent on ambient temperature and overall sys tem charge This charge must be manually recovered A recovery system will be required to remove final quantity of refrigerant from indoor coil and line set 9 Remove power from indoor and outdoor unit prior to ser vicing unit Pump Down Using 2 stg HP Tstat 288BNV Non Communicating Because this system has an inverter controlled compressor suction pressure transducer and EXV conventional procedure cannot be used to pump down and isolate the refrigerant into the outdoor unit 1 Connect gauges to 288BNV liquid and vapor service valve ports to monitor operating pressures during and completion of the procedure 2 Force system to operate in high stage by creating a large differential between room temperature and set point on thermostat Use multi meter to verify that 24 VAC is present between C and Y1 and Y2 terminals at outdoor unit 3 Close the liquid service valve 4 The unit will continue to run until high or low pressure switches open Close vapor service valve once compressor shuts down 5 Remove power from indoor and heat pump unit prior to servicing unit 6 A quantity of charge will remain in isolated section of system dependent on ambient temperature and overall system charge This charge must be manually recovered A recovery system will be required to remove final quantity o

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