Carrier Residential Air Conditioners and Heat Pumps Application Manualline
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Carrier Residential Air Conditioners and Heat Pumps Application Manualline

Residential air conditioners and heat pumps using r-22 and puron refrigerant
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Residential Air Conditioners and Heat Pumps
Using R---22 and Puronr Refrigerant
UNIT IDENTIFICATION
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Application Guideline
and Service Manual

TABLE OF CONTENTS

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Summary of Contents for Carrier Residential Air Conditioners and Heat Pumps

  • Page 1: Table Of Contents

    Residential Air Conditioners and Heat Pumps Using R---22 and Puronr Refrigerant Application Guideline and Service Manual TABLE OF CONTENTS PAGE PAGE UNIT IDENTIFICATION ......REFRIGERATION SYSTEM REPAIR .

  • Page 2: Unit Identification

    UNIT IDENTIFICATION This section explains how to obtain the model and serial number Troubleshooting Charts for Air Conditioners and Heat Pumps are from unit rating plate. These numbers are needed to service and provided in the appendix at back of this manual. They enable the repair the Puronr and R- -22 air conditioner or heat pump.

  • Page 3: Safety Considerations

    SAFETY CONSIDERATIONS INSTALLATION GUIDELINE Residential New Construction Installation, service, and repair of these units should be attempted only by trained service technicians familiar with standard service Specifications for these units in the residential new construction instruction and training material. market require the outdoor unit, indoor unit, refrigerant tubing sets, All equipment should be installed in accordance with accepted metering device, and filter drier listed in Product Data (PD).

  • Page 4: Accessories And Descriptions

    ACCESSORIES Table 1—Required Field- -Installed Accessories for Air Conditioners REQUIRED FOR REQUIRED FOR LOW --- AMBIENT REQUIRED FOR SEA COAST ACCESSORY COOLING APPLICATIONS LONG LINE APPLICA- APPLICATIONS (Below 55°F/12.8_C) TIONS* (Within 2 miles/3.22 km) Ball Bearing Fan Motor Yes {} Compressor Start Assist Capacitor and Relay Yes** Crankcase Heater...

  • Page 5: Accessory Descriptions

    Suggested for all commercial applications. 5. Outdoor Air Temperature Sensor Designed for use with Carrier Thermostats listed in this publication. This device enables the thermostat to display the outdoor temperature. This device is required to enable special thermostat features such as auxiliary heat lock out.

  • Page 6: Low- -Ambient Guideline

    LOW- -AMBIENT COOLING GUIDELINE The minimum operating temperature for these units in cooling Comfort Series models and Fig. NO TAG for Deluxe models. First mode is 55_F/12.7_C outdoor ambient without additional production of Performance units are capable of low ambient accessories.

  • Page 7: Long Line Guideline

    LONG LINE GUIDELINE CABINET ASSEMBLY Basic Cabinet Designs Refer to Residential Piping and Long Line Guideline for air conditioner and heat pump systems using Puron refrigerant or Certain maintenance routines and repairs require removal of the Long Line Guideline for R- -22 Air Conditioners and Heat Pumps. cabinet panels.
  • Page 8 Access Compressor Or Other Internal Cabinet Components NOTE: It is not necessary to remove the top cover to gain access. Remove Fan Motor Assembly - - Mid- -Tier / Deluxe Removing the top cover may cause grill panels, corner posts, 1.
  • Page 9 Base and Comfort Series AC Control Box Base and Comfort HP Control Box Fig. 4 – Base and Comfort Series Control Box Identification...
  • Page 10 Labeling Wiring Label Charging Label Rating Plate Caution Label (3-phase only) Piston Label Warning Label Mid ---Tier / Deluxe Wiring Label Rating Plate Charging Label Caution Label Piston Label Warning Label Entry Fig. 5 – Label Locations...

  • Page 11: Electrical

    ELECTRICAL 3. Reconnect leads and apply low- -voltage power to contactor coil. This may be done by leaving high- -voltage power to outdoor unit off and turning thermostat to cooling. Check WARNING voltage at coil with voltmeter. Reading should be between 20v and 30v.

  • Page 12: Cycle Protector

    This delay enables blower to remove residual cooling in coil after Cycle Protector compression shutdown, thereby improving efficiency of system. Carrier thermostats have anti- -cycle protection built in to protect the The sequence of operation is that on closure of wall thermostat and compressor.

  • Page 13: Pressure Switches

    Pressure Switches High- -Pressure Switch (AC & HP) The high- -pressure switch is located in liquid line and protects Pressure switches are protective devices wired into control circuit against excessive condenser coil pressure. It opens around 610 or (low voltage). They shut off compressor if abnormally high or low 670 psig for Puron and 400 psig for R22 (+/- - 10 for both).

  • Page 14: Defrost Thermostat

    When the cycle is complete, R- -Y is turned off and compressor and outdoor fan should stop. With Carrier thermostats, the O terminal remains energized in the cooling mode. If the mode is switched to heat or Off, the valve is de- -energized.

  • Page 15: Defrost Control Speed- -Up Timing Sequence

    Troubleshooting (HK32EA001) 3. If all voltages are present and unit will still not run defrost, remove thermostat pigtail harness from board and perform If outdoor unit will not run: checks directly on input pins with jumper wires. The pigtail 1. Does the Y input has 24 volts from thermostat? If not, may have a bad connection or be mis- -wired.

  • Page 16: Defrost Control Board

    When the cycle is complete, R- -Y is turned off and compressor and screwdriver. outdoor fan should stop. When using Carrier thermostats, the 7. Unit changes over to defrost within 21 sec (depending on reversing valve remains energized in the cooling mode until the timing cycle setting).

  • Page 17: Fan Motor

    Fan Motor If the defrost thermostat is closed, a complete defrost cycle is initiated. If the Quiet Shift switch is turned on, the compressor will The fan motor rotates the fan blade that draws air through the be turned off for two 30 second intervals as explained previously. outdoor coil to exchange heat between the refrigerant and the air.

  • Page 18: Copeland Scroll Compressor

    COPELAND SCROLL COMPRESSOR LG SCROLL COMPRESSOR The compressors used in these products are specifically designed to operate with designated refrigerants and cannot be interchanged. LG produced scroll compressors are designed to operate and Scroll Gas Flow function as the typical orbiting scroll on a fixed scroll design. Compression in the scroll is Refrigerant flow and compression is basically the same.
  • Page 19 If replacement is deemed necessary, perform the following to replace sensor: 1. Locate top cap and discharge temperature sensor 2. Carefully remove sensor cover A12343 A12342 3. Expose the sensor holder 4. Slide out the sensor, slide in replacement and reinstall the cover A12344 A12345...

  • Page 20: Compressor Troubleshooting

    COMPRESSOR TROUBLESHOOTING Noisy Compressor Noise may be caused by a variety of internal and external factors. Compressor Failures Careful attention to the “type” of noise may help identify the Compressor failures are classified in 2 broad failure categories; source. The following are some examples of abnormal conditions mechanical and electrical.
  • Page 21 9. If a compressor hums but won’t start it could indicate either a voltage or amperage issue. Verify adequate voltage and operational start components if installed. If it is drawing excessive amperage and voltage doesn’t appear to be the problem it may be assumed a locked condition. Ensure refrigerant has had ample time to equalize and boil out of the compressor before condemning.

  • Page 22: Electrical Failures

    Electrical Failures CAUTION The compressor mechanical pump is driven by an electric motor within its hermetic shell. In electrical failures, compressor does not UNIT DAMAGE HAZARD run although external electrical and mechanical systems appear normal. Compressor must be checked electrically for abnormalities. Failure to follow this caution may result in equipment damage or improper operation.

  • Page 23: Refrigeration System

    REFRIGERATION SYSTEM Brazing This section on brazing is not intended to teach a technician how to Refrigerant braze. There are books and classes which teach and refine brazing techniques. The basic points below are listed only as a reminder. WARNING Definition: The joining and sealing of metals using a nonferrous metal having a melting point over 800_F/426.6_C.
  • Page 24 Pumpdown Procedure Before brazing the line set to the valves, the belled ends of the sweat connections on the service valves must be cleaned so that no Service valves provide a convenient shutoff valve useful for certain brass plating remains on either the inside or outside of the bell refrigeration- -system repairs.
  • Page 25 Heating Piston (AccuRaterr) - - Heat Pumps Only In this product line, AccuRater pistons are used to meter refrigerant for heat pump heating mode only. All indoor coils are supplied with a bi- -flow TXV for metering in the cooling mode. AccuRaterr piston has a refrigerant metering hole through it.
  • Page 26 Reversing Valve If valve is defective: In heat pumps, changeover between heating and cooling modes is 1. Shut off all power to unit and remove charge from system. accomplished with a valve that reverses flow of refrigerant in 2. Remove solenoid coil from valve body. Remove valve by system.

  • Page 27: Liquid Line Filter Drier

    Liquid Line Filter Drier Install Liquid- -line Filter Drier Indoor - - HP Refer to Fig. 21 and install filter drier as follows: Filter driers are specifically designed for R- -22 or Puronr refrigerant. Only operate with the appropriate drier using factory 1.

  • Page 28: Accumulator

    Accumulator CAUTION The accumulator is specifically designed to operate with Puronr or R22 respectfully; use only factory- -authorized components. PERSONAL INJURY HAZARD Under some light load conditions on indoor coils, liquid refrigerant is present in suction gas returning to compressor. The accumulator Failure to follow this caution may result in personal injury.

  • Page 29: Thermostatic Expansion Valve (Txv)

    Thermostatic Expansion Valve (TXV) IMPORTANT: The TXV should be mounted as close to the indoor coil as possible and in a vertical, upright position. Avoid All fan coils and furnace coils will have a factory installed mounting the inlet tube vertically down. The valve is more thermostatic expansion valve (TXV).

  • Page 30: Make Piping Connections

    Replacing TXV on an Indoor Coil (pre- -2006) 10. Attach TXV bulb to vapor tube inside cabinet, in same location as original was when removed, using supplied bulb 1. Pump system down to 2 psig and recover refrigerant. clamps (nylon or copper). See Fig. 23 for correct 2.

  • Page 31: Refrigeration System Repair

    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 LEAK nitrogen (less expensive than refrigerant).

  • Page 32: Compressor Removal And Replacement

    Compressor Removal and Replacement System Clean- -Up After Burnout Once it is determined that compressor has failed and the reason Some compressor electrical failures can cause motor to burn. When established, compressor must be replaced. this occurs, by- -products of burn, which include sludge, carbon, and acids, contaminate system.

  • Page 33: Evacuation

    CHECK CHARGE Evacuation Proper evacuation of the system will remove non- -condensibles (See Charging Tables 10 & 12) and assure a tight, dry system before charging. The two methods Factory charge amount and desired subcooling are shown on unit used to evacuate a system are the deep vacuum method and the rating plate.
  • Page 34 TROUBLESHOOTING WITH SUPERHEAT Low Superheat with Normal or Low Suction Pressure This troubleshooting routine was developed to diagnose cooling problems using superheat in TXV systems. It is effective on heat NOTE: Normal or low suction pressure is considered for pumps in cooling mode as well as air conditioners. The system R- -22: <...

  • Page 35: Fitting Losses In Equivalent Feet

    High Superheat with Normal or High Suction Pressure Pseudo Evaporator Superheat Instructions NOTE: Normal to High suction pressure is considered The Pseudo Evaporator Superheat calculates the superheat at the outlet of the evaporator with known and available information. for R- -22: > ∼65 psig, Puron: > ∼110 psig. An application issue or Because there generally is not a pressure port on the vapor line at other system component failure typically causes this condition.

  • Page 36: Puron System Suction Pressure Drop

    Table 5—Puron System Suction Pressure Drop Puron Suction Line Pressure Drop (psig) Nominal Suction Line Pressure Suction Size Drop Velocity Total Equivalent Line Length (ft) (Btuh) (in.) (psi/100 ft) 1649 18000 18000 1018 18000 16.7 2199 1357 24000 24000 24000 1696 30000 30000...

  • Page 37: R- -22 System Suction Pressure Drop

    Table 6—R- -22 System Suction Pressure Drop R ---22 Suction Line Pressure Drop (psig) Nominal Line Pressure Suction Size Drop Velocity Total Equivalent Line Length (ft) (Btuh) (in.) (psi/100 ft) 13.6 2563 18000 1539 18000 18000 1025 18000 2052 24000 24000 1367 24000...
  • Page 38 Table 7—Puronr Refrigerant Pressure Temperature Chart PSIG PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG °F --38.2 39.9 76.9 102.9 123.3 140.2 --35.3 40.8 77.4 103.3 123.6 140.5 --32.5 41.6 78.0 103.7 124.0 140.8 --29.9 42.5 78.5 104.1 124.3 141.1...
  • Page 39 Table 8—R- -22 Refrigerant Pressure Temperature Relationship psig psig psig psig psig psig psig °F °F °F °F °F °F °F - -25.9 41.7 76.2 101.1 120.9 137.5 152.0 - -24.0 42.3 76.7 101.4 121.1 137.8 152.2 - -22.1 43.0 77.1 101.7 121.4...

  • Page 40: Puron Subcooling Chart

    Table 9—Puron Subcooling Chart Liquid Line Temperature (_F) Liq Press P---T Subcooling (_F) (_F) (psig)

  • Page 41: Puron Superheat Chart

    Table 10—Puron Superheat Chart Vapor Line Temperature (°F) Superheat (°F) Vap Press P- -T (°F) (psig)

  • Page 42: R- -22 Subcooling Chart

    Table 11—R- -22 Subcooling Chart R---22 Liquid Line Temperature (_F) Liquid Subcooling (_F) PT (°F) Pres (psig) 103 101 105 103 101 106 104 102 100 108 106 104 102 100 109 107 105 103 101 109 107 105 103 101 112 110 108 106 104 102 100 114 112 110 108 106 104 102 100 115 113 111...

  • Page 43: Troubleshooting With Superheat

    Table 12—R- -22 Superheat Chart R---22 Vapor Line Temperature (_F) Vapor Superheat (_F) PT (°F) Press (psig)

  • Page 44: Two- -Stage 25Hnb/24Anb

    TWO- -STAGE 25HNB/24ANB Application Guidelines Model Plug Carrier designed and tested the two- -stage air conditioner and heat Each control board contains a model plug. The correct model plug pump products with Puron refrigerant to operate at a minimum must be installed in order for the system to operate properly. (See outdoor operating ambient in cooling mode at 55_F without low Table 13.)

  • Page 45: Airflow Selections For 24Anb7 / 25Hnb6 / 24Anb1 /25Hnb9 Using Non- -Communicating (Non- -Infinity) Thermostats

    Airflow Selections for 24ANB7 / 25HNB6 / Low pressure switch is ignored for first 3 minutes during 24ANB1 /25HNB9 Using Non- -Communicating low ambient start up. After 3 minutes, if LPS trips, then outdoor fan motor is turned off for 10 minutes, with the (Non- -Infinity) Thermostats compressor running.

  • Page 46: Check Charge

    has been reached, the compressor will be energized then the The ODF fan delay defeat can be toggled by shorting the outdoor fan will be de- -energized at which time the normal defrost forced defrost pins for >15 seconds while in the standby cycle begins.
  • Page 47 Utility Interface With Infinity Control refrigerant charge may not be correct. Do not use chart to adjust refrigerant charge. The utility curtailment relay should be wired between R and Y2 NOTE: In heating mode, check refrigerant charge only when connections on the control board for Infinity Communicating pressures are stable.
  • Page 48 ECM Fan Motor Troubleshooting The outdoor Integral Control Motor (ECM), is a variable- -speed motor which operates from 450 to 850 rpm. The motor is a dc If the outdoor fan motor fails to start and run: permanent magnet- -type motor with the electronic controls Check the high- -voltage supply.
  • Page 49 Muffler, Accumulator, Reversing Valve (RVS) Control Box The Puronr two- -stage air conditioners and heat pumps have a Contactor And Capacitor compressor discharge line muffler, to dampen sound pressure Removal of the information plate exposes the control components. pulsations. Both air conditioner and heat pump control boxes will appear to be The Puronr two- -stage heat pumps have a specifically designed nearly identical.

  • Page 50: Troubleshooting

    A B C A B C A B C A B C UTILITY RELAY UTILITY SIGNAL OPEN RELAY Liquid Line Solenoid * SUPPLIED BY UTILITY PROVIDER A12260 A12261 Fig. 33 – 2- -Stage Control Board TROUBLESHOOTING Pressure Switch Protection Troubleshooting circuit board The outdoor unit is equipped with high- - and low- -pressure HK38EA016, 022, 023 switches.
  • Page 51 230v Brown- -Out Protection Defeated Low or High Contactor Open / No 230V at Compressor Contractor The brownout feature can be defeated if needed for severe noisy power conditions. This defeat should always be a last resort to 24ANB1/24ANB7/25HNB6/25HNB9 solving the problem. Defeat is available on the User Interface If the compressor voltage is not sensed when the compressor setup screen (available with SYSTXBBUID01- -C UI) or can be should be starting, the appropriate contactor may be stuck open or...
  • Page 52 Temperature Thermistors The thermistor comparison is not performed during low ambient cooling or defrost operation. Thermistors are electronic devices which sense temperature. As the Failed Thermistor Default Operation temperature increases, the resistance decreases. Thermistors are used to sense outdoor air (OAT) and coil temperature (OCT). Factory defaults have been provided in the event of failure of Refer to Fig.

  • Page 53: Troubleshooting

    Table 15—Two- -Stage Compressor Resistances (Winding Resistance at 70_F±20_) Winding Start (S- - C) 1.64 1.52 1.86 1.63 Run (R- - C) 1.30 0.88 0.52 0.39 Status Codes Table 16 shows the status codes flashed by the amber status light. The short flash is 0.25 seconds ON and the long flash is 1.0 second Most system problems can be diagnosed by reading the status code ON.
  • Page 54 Thermidistat Fan Coil Heat Pump Thermidistat Furnace Heat Pump RVS Cooling O/B W2 RVS Cooling O/B W2 J2 Jumper Heat Stage 3 W/W1 W/W1 (furnace) Heat Stage 3 W/W1 on Control Board Heat/Cool Stage 1 Y1 / W2 Heat/Cool Stage 1 Y1 / W2 Heat/Cool Stage 2 Y/Y2...

  • Page 55: Two Stage Non- -Communicating 24Acb7/25Hcb6

    TWO STAGE NON- -COMMUNICATING 24ACB7/25HCB6 Airflow Selection for Variable Speed Furnaces These units cost 2- -stage option that non- -communicating utilizing 2 stage scroll technology. These (non- -communicating) units require Performance Boost furnace (58PH, 58MEB), variable The variable speed furnaces provide blower operation to match the speed furnace (58MV, 58CV) or new model variable speed fan coil capacities of the compressor during high and low stage cooling (FV4C).

  • Page 56: System Function And Sequence Of Operation

    Quiet Shift SYSTEM FUNCTION AND SEQUENCE Quiet shift is a field selectable defrost mode (factory set to OFF), OF OPERATION (24ACB7/25HCB6) which will eliminate occasional noise that could be heard at the start of defrost cycle and restarting of heating cycle. It is selected NOTE: Defrost control board is equipped with 5 minute lockout timer that is initiated upon any interruption of power.

  • Page 57: Check Charge

    Heating Check Chart Procedure To check system operation during heating cycle, refer to the Heating Check Chart on outdoor unit. This chart indicates 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.

  • Page 58: Care And Maintenance

    CARE AND MAINTENANCE Cleaning Coil 1. Remove top cover. (See Remove Top Cover in Cabinet To assure high performance and minimize possible equipment section of this manual.) malfunction, it is essential that maintenance be performed 2. Remove coil grilles or louvers (as applicable) to gain full periodically on this equipment.

  • Page 59: Puron Quick Reference Guide

    Electrical Controls and Wiring Final Check- -Out 1. Disconnect power to both outdoor and indoor units. After the unit has been operating, the following items should be checked. 2. Check all electrical connections for tightness. Tighten all screws on electrical connections. If any connections appear 1.

  • Page 60: Ac Troubleshooting Chart

    AIR CONDITIONER TROUBLESHOOTING CHART NO COOLING OR INSUFFICIENT COOLING COMPRESSOR COMPRESSOR RUNS BUT RUNS BUT COMPRESSOR CYCLES ON INSUFFICIENT WILL NOT RUN INTERNAL COOLING OVERLOAD OUTDOOR FAN HIGH SUCTION HIGH SUCTION CONTACTOR CONTACTOR STOPPED OR LOOSE LEAD LOW SUCTION LOW HEAD OPEN CLOSED CYCLING ON...

  • Page 61: Hp Troubleshooting Chart - - Heating Cycle

    HEAT PUMP TROUBLESHOOTING HEATING CYCLE NO HEATING OR INSUFFICIENT HEATING COMPRESSOR COMPRESSOR RUNS BUT RUNS COMPRESSOR CYCLES ON INSUFFICIENT WILL NOT RUN INTERNAL HEATING OVERLOAD DIRTY FILTERS CONTACT CONTACTOR LOW SUCTION STRIP HEATERS OR INDOOR OPEN CLOSED LOW HEAD NOT OPERATING COIL INDOOR FAN DEFECTIVE LOW-...

  • Page 62: Hp Troubleshooting Chart - - Cooling Cycle

    HEAT PUMP TROUBLESHOOTING COOLING CYCLE NO COOLING OR INSUFFICIENT COOLING COMPRESSOR COMPRESSOR RUNS BUT RUNS BUT COMPRESSOR CYCLES ON INSUFFICIENT WILL NOT RUN INTERNAL COOLING OVERLOAD OUTDOOR FAN HIGH SUCTION HIGH SUCTION STOPPED OR CONTACTOR CONTACTOR LOOSE LEAD LOW SUCTION LOW HEAD OPEN CLOSED...

  • Page 63: Index Of Tables

    INDEX OF TABLES DESCRIPTION TABLE # Required Field- -Installed Accessories for Air Conditioners ............. . . Required Field- -Installed Accessories for Heat Pumps .
  • Page 64 Catalog No.24---25---4SM Copyright 2012 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Edition Date: 07/12 Replaces:New Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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