Carrier Infinity 24VNA6 Series Service Manual

Carrier Infinity 24VNA6 Series Service Manual

Variable speed air conditioner and heat pump
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24VNA6 / 25VNA4
Infinity® Series
Variable Speed Air conditioner and Heat Pump
with Greenspeed Intelligence
2 to 5 Nominal Tons
Table of contents
UNIT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Aluminum Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . 3
Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Compressor / Fan Sub-System . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Variable Frequency Drive (VFD) . . . . . . . . . . . . . . . . . . . . . . . . 5
VFD Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
High Pressure Switch (HPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Compressor Brushless Permanent Magnet Motor (BPM) . . . . . 5
VFD + Compressor BPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fan Brushless Permanent Magnet Motor (BPM) . . . . . . . . . . . . 5
VFD + Fan BPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONTROL SUB-SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Primary Control Module (PCM). . . . . . . . . . . . . . . . . . . . . . . . . 5
Control Connection (Communicating and Non-Communicating). 6
Communicating Infinity Control . . . . . . . . . . . . . . . . . . . . . . . . 6
Non-Communicating Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 1 – DIP Swtich Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PCM Indicators and Matrix Display . . . . . . . . . . . . . . . . . . . . . . 6
Model Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VFD Control Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Equalization Valve (PEV) . . . . . . . . . . . . . . . . . . . . . . 8
Reversing Valve (RVS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heating Electronic Expansion Valve (EXV-H) . . . . . . . . . . . . . 8
Bluetooth® Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Accessory Control Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Utility Curtailment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Liquid Line Solenoid Valve (LLS) . . . . . . . . . . . . . . . . . . . . . . . 8
CONTROL FEATURES AND OPERATION . . . . . . . . . . . . . . . . . . 9
Equipment Configuration (Model Plug) . . . . . . . . . . . . . . . . . . . . 9
Performance Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compressor Protect Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compressor Reliability Protection . . . . . . . . . . . . . . . . . . . . . . . 9
Sump Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intermittent Low Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fan Operating Exceptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cooling Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Manual
PAGE NO.
Heating Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Super Heat Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Defrost Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Defrost Interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Defrost Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PCM Indicators and Display Operation. . . . . . . . . . . . . . . . . . . . 10
Status Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Comm Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VFD Comm Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Matrix Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reprogrammability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VFD LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 2 – VFD LED Indicator Functions . . . . . . . . . . . . . . . . . . 11
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING CONTROL FEATURES . . . . . . . . . . . 12
SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table 3 – Model Plug Information. . . . . . . . . . . . . . . . . . . . . . . . 13
COMPONENT DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 4 – Variable Speed Compressor Resistances (ohm)
(winding resistance at 68°F /20°C) . . . . . . . . . . . . . . . . . . . . . . . 14
Table 5 – DC Voltage and PWM Measurement . . . . . . . . . . . . . 14
Table 6 – Thermistor Resistance (k-ohms) vs. Temperature. . . . 14
DIAGNOSTIC CODES AND TROUBLESHOOTING . . . . . . . 17
Table 7 – Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Servicing Systems on Roofs With Synthetic Materials . . . . . . . . 35
Synthetic Roof Precautionary Procedure . . . . . . . . . . . . . . . . . 35
Brazing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Service Valves and Pumpdown . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pumpdown & Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Evacuation and Recovery of Refrigerant from 25VNA4 . . . . . 36
Reversing Valve (25VNA4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Liquid Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Install Liquid-line Filter Drier Indoor. . . . . . . . . . . . . . . . . . . . 37
Suction Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Thermostatic Expansion Valve (TXV) . . . . . . . . . . . . . . . . . . . . 37
TXV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Vapor Injection Operation (5 Ton Models) . . . . . . . . . . . . . . . . . 38
Vapor Injection Electronic Exp. Valve (EXV VI)
(5 Ton Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REFRIGERATION SYSTEM REPAIR. . . . . . . . . . . . . . . . . . . . . . 39
Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
PAGE NO.

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Summary of Contents for Carrier Infinity 24VNA6 Series

  • Page 1 24VNA6 / 25VNA4 Infinity® Series Variable Speed Air conditioner and Heat Pump with Greenspeed Intelligence 2 to 5 Nominal Tons Service Manual Table of contents PAGE NO. PAGE NO. UNIT IDENTIFICATION ....... . . 2 Heating Control .
  • Page 2: Unit Identification

    24VNA6 / 25VNA4: Service Manual 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 Product Major Minor...
  • Page 3: Electrical System Overview

    24VNA6 / 25VNA4: Service Manual ELECTRICAL COMPRESSOR & WARNING FAN SUB-SYSTEM ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. TRANSFORMER 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.
  • Page 4 24VNA6 / 25VNA4: Service Manual VFD SUB-SYSTEM COMPRESSOR REACTOR(S) FILTER 1 on 2, 3 ton 2 on 4, 5 ton Line Power Fig. 2 – Compressor / Fan Sub-System Diagram Fig. 3 – Wiring Diagram — 24VNA6 / 25VNA4 Model sizes 2 - 5 tons, 208/230-1 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 5: Control Sub-System

    The PCM contains indicators and displays to provide operating status depending on air movement requirements. and conditions. The PCM also supports communication with the Carrier The fan on-board VFI will automatically limit fan speed if fan load Service Tech App through the Bluetooth Module which provides current reaches operating limits.
  • Page 6 24VNA6 / 25VNA4: Service Manual Control Connection (Communicating and Table 1 – DIP Swtich Settings Non-Communicating) Switch 1 Switch 2 Defrost Interval The primary system control interface for the PCM is the communicating Auto Infinity Control. The PCM also supports traditional 24VAC discrete Down 30 minutes control signals in an emergency mode of operation when a...
  • Page 7 24VNA6 / 25VNA4: Service Manual Bluetooth Service Port A200049 Status LED (Yellow) CCN Communication LED (Green) VFD LED (Red / Green) VFD-PCM Communication Port A200044 Fig. 7 – PCM Control Board Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 8 The Bluetooth Module is a wireless service communication device allowing the equipment to communicate with the Carrier Service Tech App. The Carrier Service Tech App can be used to retrieve diagnostic information, equipment operating history, and reprogram the PCM or the VFD.
  • Page 9 24VNA6 / 25VNA4: Service Manual CONTROL FEATURES AND OPERATION Some systems use an external Crankcase Heater installed around the bottom portion of the compressor. Other systems may use a stator Equipment Configuration (Model Plug) heating function where the VFD flows a DC current through the motor The PCM detects the model plug value at power-up and configures windings.
  • Page 10 8. Compressor ramps to heating speed The software can also be updated from the Carrier Service Tech App via 9. Fan turns on when coil temperature falls to ambient temperature the Bluetooth Module. This is the only software update method for PCM Indicators and Display Operation equipment using non-communicating control systems.
  • Page 11 24VNA6 / 25VNA4: Service Manual VFD LEDs WARNING The VFD is equipped with several LEDs that indicate different statuses. ELECTRICAL HAZARD - HIGH VOLTAGE! Failure to follow this warning could result in personal injury or death. Electrical components may hold charge. DO NOT remove control box cover for 2 minutes after power has been removed from unit.
  • Page 12: System Diagnostics

    24VNA6 / 25VNA4: Service Manual TROUBLESHOOTING TROUBLESHOOTING CONTROL FEATURES Diagnostics Display Diagnostic Code Recall Active diagnostics will be continuously displayed on the matrix display The Diagnostic Code Recall mode will be enabled if the Forced Defrost on the PCM. Active diagnostics can also be displayed on the system pins are shorted when power is applied to the equipment.
  • Page 13: Component Diagnostics

    24VNA6 / 25VNA4: Service Manual 5. Loose fitting connections or wire breaks will also simulate a high pressure switch trip if the discharge pressure is high. Otherwise, a loose fitting or wire break will simulate a VFD communication MAIN PCM POWER TRANS error.
  • Page 14 24VNA6 / 25VNA4: Service Manual Table 4 – Variable Speed Compressor Resistances (ohm) Table 6 – Thermistor Resistance (k-ohms) vs. Temperature (winding resistance at 68°F /20°C) Temp (F) OAT-OCT-OST WINDING Between terminals T1, T2, and T3 0.453 0.424 0.424 (U,V,W) Between terminal &...
  • Page 15 EQUIPMENT DAMAGE HAZARD gauge port fitting and compare the gauge reading with the pressure reported by the PCM to the Infinity Control or to the Carrier Service Failure to follow this caution may result in equipment damage or Tech App. The connections at the PCM should be swapped to ensure the improper operation.
  • Page 16 24VNA6 / 25VNA4: Service Manual Electronic Expansion Valves (EXV, Fig. While the EXV-H and EXV-VI valve bodies are different for different models, the stator for all valves have the same electrical properties. The EXV coil resistance should fall between 43 and 49 ohms when measured from common to remaining terminals.
  • Page 17 If no green or red led is present on the Bluetooth module, disconnect harness at the Bluetooth module and check for 18-30 The Bluetooth module used with Carrier Service Tech App can collect VAC between pins 1 and 3 at the Bluetooth module connector end of recent fault codes, monitor system operation, and update software.
  • Page 18 PCM should be reprogrammed soft low pressure limit can be exceeded for up to 2 minutes before code manually using the Infinity Control or the Carrier Service Tech App. is generated, while exceeding the hard limit immediately results in code Code 26-31 External EEPROM Write Failure 32-15.
  • Page 19 24VNA6 / 25VNA4: Service Manual Code 33-15 Compressor Low Discharge Shutdown 100psi. The fault will clear and unit will start normally once pressure differential is below 100psi and demand is still present. Code 33-55 Compressor Low Discharge Lockout The most likely cause of this fault is a non-functioning PEV. Possibly the Code 33-15 will become active if compressor is running and discharge PEV suffered a mechanical failure, or the coil is not mounted to PEV.
  • Page 20 24VNA6 / 25VNA4: Service Manual Code 39-14 Fan Speed Error Code 51-02 OAT Shorted A code 39-14 is declared when the commanded speed is greater than The outdoor air thermistor determines operating range of compressor 200rpm and differs from actual speed (as reported from fan to VFD) by and fan speeds in cooling and heating operating modes.
  • Page 21 24VNA6 / 25VNA4: Service Manual Code 53-42 OST Shorted - Backup Heat Only Code 57-02 P1 Shorted Fault Code 57-42 P1 Shorted Lockout The suction thermistor is required for control of the outdoor EXV in HP systems. Similar to "OST Open" fault, heating mode operation will be Code 58-02 P2 Shorted Fault locked out if the OST is determined to be open or shorted.
  • Page 22 24VNA6 / 25VNA4: Service Manual Remove PEV connector from PCM and measure continuity between test itself by operating to a known position as the valve does not have the pins 1 & 3. If open, inspect wire for damage and repair if necessary. If no capability to feedback actual position.
  • Page 23 24VNA6 / 25VNA4: Service Manual Code 81-13 VFD System Fault - PFC within a 1 hour period will result in a code 82-55 and 2 hour lockout. Occasional occurrences of this code may happen due to momentary Code 81-53 VFD System Lockout - PFC power loss or electrical noise from utility.
  • Page 24 VFD should be reprogrammed manually Code 85-53 VFD System Lockout - DC Under Volt using the Infinity Control or the Carrier Service Tech App. The VFD boosts line voltage and uses the PFC circuit to maintain DC Code 88-31 VFD Internal Fault - Current Sensor voltage within an acceptable range.
  • Page 25 24VNA6 / 25VNA4: Service Manual Code 88-34 VFD Internal Fault - PFCM Sensor A Code 88-39 VFD Internal Fault - Microprocessor Code 88-74 VFD Lockout - PFCM Sensor A Code 88-79 VFD Internal Lockout - Microprocessor The VFD has internal current measurement to protect PFC components This VFD has internal diagnostics to verify that the microprocessor is from exceeding current thresholds that may shorten the VFDs operating operating sufficiently to maintain safe compressor and fan operation.
  • Page 26 24VNA6 / 25VNA4: Service Manual Table 7 – Fault Code Table Code* Description Expansion Base Fault** Malfunction*** System Control Software Upgrade Needed Line Voltage Low Line Voltage High PCM-Bluetooth Module Communication Failure Indoor Coil Freeze Protection 5V PCM External Power Out of Range Invalid Model Plug Model Plug Missing Model Plug Changed...
  • Page 27 24VNA6 / 25VNA4: Service Manual Table 7 – Fault Code Table (Continued) Code* Description Expansion Base Fault** Malfunction*** EXV-H Phase Open EXV-H Power Short to Ground EXV-H Phase Short to Ground EXV-VI Phase Open EXV-VI Power Short to Ground EXV-VI Phase Short to Ground VFD Control Relay Coil Open VFD Control Relay Coil Shorted PFC Error...
  • Page 28 24VNA6 / 25VNA4: Service Manual A200188 Fig. 20 – 4T/5T Control Box Note: 4T VFD similar, not exact. 5T reactors have additional chokes A200187 to meet FCC requirement Fig. 19 – 2T/3T Control Box A200189 Fig. 21 – 2T/3T VFD A200190 Fig.
  • Page 29 24VNA6 / 25VNA4: Service Manual VFD main power  relay.  Terminals  are not used.  Reactor connection  HPS connection (non  VFD control relay  replaceable fuse is  and LED  directly above)  DC+, DC‐ terminals  Fan motor fuse  Compressor UVW  Fan motor connections  connections  VFD to PCM comm  connection  A200191 Fig. 23 – 2/3T VFD Connections Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 30 24VNA6 / 25VNA4: Service Manual Fan motor connections  Compressor UVW  DC+, DC‐ terminals  connections  VFD to PCM comm  connection  Reactor connection  Fan motor fuse  (hidden behind  resistors) VFD main power  VFD control relay  relay.  Terminals  and LED  are not used.  HPS connection (non  Filter board input  replaceable fuse is  directly above)  A200192 Fig. 24 – 4/5T VFD Connections Note: 4T uses separate terminals Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 31 24VNA6 / 25VNA4: Service Manual A200193 Fig. 25 – PCM (used on all models) Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 32 24VNA6 / 25VNA4: Service Manual A200194 Fig. 26 – Bluetooth Module (used on all models) A200195 Fig. 27 – Fan Motor (used on all models) A200197 Fig. 29 – 5T Reactor (Note: 5T uses 2 reactors) A200196 A200198 Fig. 28 – 2/3/4T Rector Fig.
  • Page 33 24VNA6 / 25VNA4: Service Manual   A200199 Fig. 31 – PCM to Bluetooth Module Comm Cable (used on all models) A200200 Fig. 32 – VFD to PCM Comm Cable (used on all models Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 34 24VNA6 / 25VNA4: Service Manual A200201 Fig. 33 – PCM Wiring Diagram Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 35: Refrigeration System

    24VNA6 / 25VNA4: Service Manual REFRIGERATION SYSTEM Brazing Refrigerant This section on brazing is not intended to teach a technician how to braze. There are books and classes which teach and refine brazing WARNING 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°F/426.6°C.
  • Page 36 24VNA6 / 25VNA4: Service Manual The service valve cannot be field repaired; therefore, only a complete Reversing Valve (25VNA4) valve or valve stem and service-port caps are available for replacement. In heat pumps, changeover between heating and cooling modes is If the service valve is to be replaced, a metal barrier must be inserted accomplished with a valve that reverses flow of refrigerant in system.
  • Page 37 24VNA6 / 25VNA4: Service Manual CAUTION FROM INDOOR COIL VIA SERVICE VALVE ON TO OUTDOOR COIL OUTDOOR COIL UNIT DAMAGE HAZARD ACCUMULATOR Failure to follow this caution may result in equipment damage or improper operation. TP-4 TP-3 TP-2 To avoid filter drier damage while brazing, filter drier must be wrapped in a heat-sinking material such as a wet cloth.
  • Page 38: Electrical Shock Hazard

    24VNA6 / 25VNA4: Service Manual TXV Operation 6. Scratch matching marks on tubing studs and old accumulator. Scratch matching marks on new accumulator. Unbraze stubs from The TXV is a metering device that is used in air conditioning and heat old accumulator and braze into new accumulator.
  • Page 39: Refrigeration System Repair

    24VNA6 / 25VNA4: Service Manual Vapor Injection Electronic Exp. Valve (EXV VI) A simple and inexpensive method of testing for leaks is to use soap bubbles. (See Fig. 41.) Any solution of water and soap may be used. (5 Ton Models) Soap solution is applied to all joints and connections in system.
  • Page 40 The Bluetooth® word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and any use of such marks by Carrier Corporation is under license. Other trademarks and trade names are those of their respective owners ©2021 Carrier. All rights reserved.

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