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Comfort PRL-series Installation Instructions Manual

Two=stage heat pump outdoor units
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INSTALLATION INSTRUCTIONS

TWO-STAGE HEAT PUMP OUTDOOR UNITS
(-)PRL-JEC 16 SEER EQUIPPED WITH THE COMFORT CONTROL
SYSTEM™
!
RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!
WARNING
!
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO
QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER
INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT.
READ THESE INSTRUCTIONS THOROUGHLY
ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOL-
LOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER
INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE
POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK,
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN
[ ] INDICATES METRIC CONVERSIONS
DO NOT DESTROY THIS MANUAL
BEFORE
2
92-20522-63-02
SUPERSEDES 92-20522-63-01

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  • Page 1: Installation Instructions

    INSTALLATION INSTRUCTIONS TWO-STAGE HEAT PUMP OUTDOOR UNITS (-)PRL-JEC 16 SEER EQUIPPED WITH THE COMFORT CONTROL SYSTEM™ RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION! WARNING THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT.

  • Page 2: Table Of Contents

    11.1 Evacuation Procedure ........17 12.0 CONDENSING UNITS EQUIPPED WITH COMFORT CONTROL SYSTEM™...

  • Page 3: Safety Information

    1.0 SAFETY INFORMATION WARNING THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOL- LOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
  • Page 4 CAUTION R-410A systems operate at higher pressures than R-22 systems. Do not use R-22 service equipment or components on R-410A equipment. CAUTION Only use evaporators approved for use on R-410A systems. Use of existing R-22 evaporators can introduce mineral oil to the R-410A refrigerant form- ing two different liquids and decreasing oil return to the compressor.

  • Page 5: General Information

    Removing this heat does not affect a thermometer. However, removing the heat held in the moisture in the air greatly increases comfort. A prop- erly sized unit removes both forms of heat, producing a comfortable living space. An oversized system cycles on and off too quickly and does not properly remove humidity, producing an uncomfortable living space.

  • Page 6: Dimensions

    DIMENSIONS AND INSTALLATION CLEARANCES (– ) P – 036 J E C AIR DISCHARGE ALLOW 60” [1524 mm] CLEARANCE EC = EQUIPPED WITH THE EC = COMFORT CONTROL EC = SYSTEM™ ELECTRICAL DESIGNATION J - 208/230-1-60 COOLING CAPACITY BTUH x 1000 (NOMINAL CAPACITY)

  • Page 7: Electrical And Physical Data

    2.4 Electrical And Physical Data TABLE 1 (-)PRL ELECTRICAL AND PHYSICAL DATA ELECTRICAL PHYSICAL Fuse or HACR Model Outdoor Coil Weight Voltage Compressor Fan Motor Minimum Circuit Breaker Phase Number Operating Full Load Circuit R-410A Frequency (Hz) Rated Load Locked Rotor Fins Amperes Ampacity...

  • Page 8: Heat Pump Location

    Several different types of protective coatings are offered in some areas. These coatings may provide some benefit, but the effectiveness of such coating materials cannot be verified by the equipment manufacturer. 3.2 Heat Pump Location Consult local and national building codes and ordinances for special installation requirements.

  • Page 9: Factory-Preferred Tie-Down Method

    FIGURE 2 RECOMMENDED ELEVATED INSTALLATION 3.7 Factory-Preferred Tie-Down Method INSTRUCTIONS IMPORTANT: These instructions are intended as a guide to securing equipment for wind-load ratings of “120 MPH sustained wind load” and “3-second, 150 MPH gust.” While this procedure is not mandatory, the Manufacturer does recommend that equipment be properly secured in areas where high wind damage may occur.

  • Page 10: Specification Of R-410A

    FIGURE 3 SCREW LOCATIONS TABLE 2 DIMENSIONS MODEL NUMBER (-)PRL-024/036/048/060 41.5 29.813 26.5 Recovery Cylinders: -400 PSIG Pressure Rating -Dept. of Transportation 4BA400 or BW400 CAUTION R-410A systems operate at higher pressures than R-22 systems. Do not use R-22 service equipment or components on R-410A equipment. 4.2 Specifications of R-410A: Application: R-410A is not a drop-in replacement for R-22;...

  • Page 11: Quick Reference Guide For R-410A

    Combustibility: At pressures above 1 atmosphere, mixture of R-410A and air can become combustible. R-410A and air should never be mixed in tanks or supply lines, or be allowed to accumulate in storage tanks. Leak checking should never be done with a mixture of R-410A and air. Leak checking can be per- formed safely with nitrogen or a mixture of R-410A and nitrogen.

  • Page 12: Interconnecting Tubing

    CAUTION When coil is installed over a finished ceiling and/or living area, it is recommended that a secondary sheet metal condensate pan be constructed and installed under entire unit. Failure to do so can result in property damage. 7.0 INTERCONNECTING TUBING 7.1 Vapor and Liquid Lines Keep all lines sealed until connection is made.

  • Page 13: Outdoor Unit Installed Above Or Below Indoor Coil

    7.3 Outdoor Unit Installed Above or Below Indoor Coil Use the following guidelines when installing the unit: Expansion Valve Coil: a. The vertical separation cannot exceed the value in Tables 4, 5 and 6. b. No changes are required for expansion valve coils. It is recommended to use the smallest liquid line size permitted to minimize the system charge.

  • Page 14: Tubing Connections

    TABLE 6 SUCTION LINE SIZE – OUTDOOR UNIT BELOW INDOOR COIL – (-)PRL HEAT PUMPS Suction Line Size 2-Stage Line Size R-410A Connection Line Size System Size (Inch O.D.) Outdoor Unit BELOW Indoor Coil (Heat Pumps) Capacity (Inch I.D.) [mm] Total Equivalent Length - Feet [m] Model [mm]...

  • Page 15: Leak Testing

    – copper to copper - 5% – Silver alloy (no flux) – copper to steel or brass - 35% – silver alloy (with flux) • Be certain both refrigerant shutoff valves at the outdoor unit are closed. • Clean the inside of the fittings and outside of the tubing with steel wool or sand cloth before soldering.

  • Page 16: Defrost Termination

    8.2 Defrost Termination Once a defrost is initiated, the defrost will continue until fourteen minutes has elapsed or the coil temperature has reached the terminate temperature. The termi- nate temperature is factory set at 70°F, although the temperature can be changed to 50°F, 60°F, 70°F or 80°F by relocating dip switches on the ICC.

  • Page 17: High & Low Pressure Controls (Hpc And Lpc)

    High pressure control (HPC) is an automatic-reset which opens near 610 PSIG and closes near 420 PSIG. The low pressure control (LPC) is an automatic-reset which opens near 15 PSIG and closes near 40 PSIG. NOTE: HPC and LPC are monitored by the Comfort Control System™. See Section 12.0. CAUTION THE COMPRESSOR HAS AN INTERNAL OVERLOAD PROTECTOR.

  • Page 18: System

    12.0 OMFORT ONTROL SYSTEM™ The Comfort Control is the next generation of the Integrated Compressor Control (ICC) and is an integral part of the Comfort Control System™ with the following features: 12.1 Control Description (see Figure 4) Dual 7-Segment LED •...
  • Page 19 • The memory card stores all unit information. • The unit information is called shared data. • The shared data is all the information needed for proper unit operation. FIGURE 5 TYPICAL COMFORT CONTROL SYSTEM™ WIRING DIAGRAM Communicating Thermostat Outdoor Unit...

  • Page 20: Comfort Control Control Wiring

    1 – Data wire 1 2 – Data wire 2 N N o o t t e e : : Comfort Control requires 18 AWG thermostat wire. N N o o t t e e : : Term dipswitches should be in “ON” position.
  • Page 21 cooling operation, an upper case “C” is displayed on the 7-segment LEDs. 2) Second Stage Cooling Operation – When the ICC receives a command for second stage cooling operation, an upper case “C” is displayed on the 7-segment LEDs. Upper case “C” indicates second stage cooling operation 3) First Stage Heating Operation - When the ICC receives a command for first stage heating operation, “h1”...

  • Page 22: Active Compressor Protection Mode

    • The 3-minute time delay can be bypassed when a command for compressor operation is present by pressing the TEST button for 1 second and releasing. The compressor will begin operation and the dual 7-segment will stop flashing. 3 3 0 0 S S e e c c o o n n d d M M i i n n i i m m u u m m R R u u n n T T i i m m e e r r •...
  • Page 23 outdoor temperature rises above 5°F. Wait until the outdoor ambient temperature rises If the HPC opens three (3) times during the same command for unit operation, the ICC • above 5°F before performing further diagnostics. will lockout the compressor to keep it from continuing to operate and flash a L” on the 7- segment LEDs followed by a “29”.

  • Page 24: Test And Fault Recall Modes

    If the ICC detects current in the start circuit without current present in the run cir- cuit, , the ICC will lockout the compressor to keep it from continuing to operate and flash a “L” on the dual 7-segment LEDs followed by a “07”. I I M M P P O O R R T T A A N N T T : : This mode of active protection must be manually reset.
  • Page 25 A maximum of six individual faults can be stored • A maximum of three consecutive identical faults are stored. • A “0” will be displayed with no faults are stored • Each fault is displayed one time with the top right hand segment of the dual 7- •...

  • Page 26: Icc Diagnostic Codes

    12.6 OMFORT ONTROL SYSTEM™ CONTROL WIRING 13.X ICC Diagnostic Codes CONVENTIONAL THERMOSTAT WIRING 13.X ICC Diagnostic Codes 13.X ICC Diagnostic Codes 13.X ICC Diagnostic Codes 13.X ICC Diagnostic Codes 13.X ICC Diagnostic Codes ICC DIAGNOSTIC CODES Descriptions of the ICC diagnostic codes are provided below: ICC Diagnostic Codes Descriptions of the ICC diagnostic codes are provided below: Descriptions of the ICC diagnostic codes are provided below:...
  • Page 27 ELECTRONICS GROUP TO ELECTRONICS GROUP TO DESCRIBE cannot supply the required airflow for DESCRIBE d3 – Airflow CFM Mismatch DESCRIBE DESCRIBE • Misapplied/wrong indoor air mover – replace DESCRIBE DESCRIBE proper system operation The indoor air mover (air handler/furnace) with properly sized air handler/furnace. P –...
  • Page 28 Dual 7-Segment Status/Possible Cause – Troubleshooting 21 – Low Pressure Control Open 21 – Low Pressure Control Open • Unit has low refrigerant charge • Unit has low refrigerant charge LEDs Display Diagnostic Description 21 – Low Pressure Control Open •...

  • Page 29: Conventional 24Vac Thermostat Control Wiring

    Control Trip three (3) consecutive HPC trips on the same The ICC detects current in the Run circuit capacitor tional thermostat. Reference section 12.2 Comfort Control System™ Control L4 – Locked Rotor L4 – Locked Rotor • Bad run capacitor •...

  • Page 30: Typical Thermostat Wiring Diagrams

    The following figures show the typical wiring diagrams with (-)HPL air handler and (-)PRL heat BR – BROWN GY – GRAY R – RED pump. Cooling and heat pump airflows may need to be adjusted for homeowner comfort once BL – BLUE O – ORANGE W –...

  • Page 31: Icc Control Operation With Conventional Thermostat Wiring

    INSERT FIGURES 7 THRU 10 HERE FRO SECTION 13.4 HERE!!!! 12.9 ICC Control Operation with Conventional Thermostat Wiring 13.X ICC Control Operation with Conventional Thermo I I n n s s t t a a l l l l a a t t i i o o n n V V e e r r i i f f i i c c a a t t i i o o n n Installation Verification •...
  • Page 32 4 4 ) ) S S e e c c o o n n d d S S t t a a g g e e H H e e a a t t i i n n g g O O p p e e r r a a t t i i o o n n - When the ICC receives a call for second stage heating operation, “H”...

  • Page 33: Active Compressor Protection Mode

    1 Second Compressor/Fan Delay The ICC starts/stops the outdoor fan one (1) second after the start/stop of the compressor • upon a call for compressor operation to minimize current inrush and/or voltage drop. 13.X Active Compressor Protection Mode 12.10 Active Compressor Protection Mode The ICC actively protects the compressor from harmful operation during a fault condition.
  • Page 34 High Pressure Control Lockout If the HPC opens three (3) times during the same call for unit operation, the ICC will • lockout the compressor to keep it from continuing to operate and flash a L” on the 7- segment LEDs followed by a “29”. Active Protection –...

  • Page 35: Test And Fault Recall Modes

    on the 7-segment LEDs followed by a “7”. IMPORTANT: This mode of active protection must be manually deactivated. Exiting Active Compressor Protection Lockout I I M M P P O O R R T T A A N N T T : : This mode of active protection must be manually reset. Three are three methods to reset the ICC after an active protection lockout: E E x x i i t t i i n n g g A A c c t t i i v v e e C C o o m m p p r r e e s s s s o o r r P P r r o o t t e e c c t t i i o o n n L L o o c c k k o o u u t t 1) Cycle the line voltage to the unit...
  • Page 36 • Each fault is displayed one time with the top right hand segment of the dual 7- segment display activated between faults. • Each fault is displayed with the most recent fault displayed first. • A maximum of six individual faults can be stored •...

  • Page 37: Electrical Wiring

    13.0 ELECTRICAL WIRING Field wiring must comply with the National Electric Code (C.E.C. in Canada) and any applicable local code. 13.1 Power Wiring It is important that proper electrical power from a commercial utility is available at the condensing unit contactor. Voltage ranges for operation are shown in Table 8. Install a branch circuit disconnect within sight of the unit and of adequate size to handle the starting current (see Table 1).

  • Page 38: Start Up & Performance

    14.0 START-UP AND PERFORMANCE Even though the unit is factory charged with Refrigerant-410A, the charge must be checked to the charge table attached to the service panel and adjusted, if required. Allow a minimum of 5 minutes of run time before analyzing charge. At initial start-up or after extended shutdown periods, make sure the heater is ener- gized for at least 12 hours before the compressor is started.

  • Page 39: Checking Refrigerant Charge

    Charge for all systems should be checked against the Charging Chart inside the access panel cover. Before using the chart, the indoor conditions must be within 2°F of desired comfort conditions and system must be run until operating conditions stabilize (15 min. to 30 min.) CAUTION THE TOP OF THE SCROLL COMPRESSOR SHELL IS HOT.

  • Page 40: Final Leak Testing

    16.4 Final Leak Testing WARNING After the unit has been properly evacuated and charged, a halogen leak detector TURN OFF ELECTRIC POWER AT should be used to detect leaks in the system. All piping within the condensing unit, THE FUSE BOX OR SERVICE evaporator, and interconnecting tubing should be checked for leaks.

  • Page 41: Replacement Of Comfort Control System™ Control Board

    SYSTEM™ CONTROL 18.2 BOARD Each control board in the Comfort Control System™ needs information specific to the unit the control is installed in. This information is called shared data because it is distributed (shared) on the HVAC network. The shared data for a unit contains information that allows the unit to operate correctly.

  • Page 42: Electrical Checks Flow Chart

    18.3 Electrical Checks Flow Chart Thermostat call For cooling, no cooling Outdoor Unit Running? Refer to panel cover/documentation for Fault Code Troubleshooting. Check fault history for other faults. Check control voltage (R and C) 7-Segment display lit? to control No call received. Y1 LED lit? 24V Systems: Check thermostat, control wiring...

  • Page 43: Cooling Mechanical Checks Flow Chart

    18.4 Cooling Mechanical Checks Flow Chart Unit Running? Go to Electrical Pressure problems? Checks Flow Chart High Head Pressure Low Head Pressure Low Suction Pressure Dirty Outdoor Coil Low on Charge Dirty Filters Inoperative Outdoor Fan Open IPR Valve Dirty Indoor Coil Overcharge Low Ambient Temperature Inadequate Indoor Air Flow...

  • Page 44: Defrost Mechanical Checks Flow Chart

    18.5 Defrost Mechanical Checks Flow Chart DEFROST SYSTEM No Defrost Incomplete Defrost Excessive Defrost Reversing Valve Stuck Poor Sensor Location Wrong Defrost Timer Setting Poor Sensor Location Failed Defrost Relay Low System Charge (doesn’t stop O.D. Fan) Welded Rev Valve Thermostat Satisfies Wind Affecting Relay...

  • Page 45: General Troubleshooting Chart

    18.6 General Trouble Shooting Chart WARNING DISCONNECT ALL POWER TO UNIT BEFORE SERVICING. CONTACTOR MAY BREAK ONLY ONE SIDE. FAILURE TO SHUT OFF POWER CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH. SYMPTOM POSSIBLE CAUSE REMEDY Unit will not run •...

  • Page 46: Service Analyzer Charts

    18.7 Service Analyzer Charts COMPRESSOR OVERHEATING SYMPTOMS POSSIBLE CAUSE CHECK/REMEDIES High superheat Low charge Check system charge Faulty metering device Restricted cap tube, TEV (TXV) Power element superheat adjustment Foreign matter stopping flow High internal load Hot air (attic) entering return Heat source on;...
  • Page 47 SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES Short cycling of compressor (cont.) Low charge Check system charge Low evaporator air flow Dirty coil Dirty filter Duct too small or restricted Faulty run capacitor Replace Faulty internal overload Replace compressor Faulty Compressor Valves Fast equalization/ Replace compressor and examine Low pressure difference...
  • Page 48 LOSS OF LUBRICATION SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES Compressor failures Line tubing too long Add oil to the recommended level Line tubing too large Reduce pipe size to improve oil return Low suction pressure Low charge Check system charge Refrigerant leaks Repair and recharge Cold, Noisy compressor - Slugging...
  • Page 49 THERMOSTATIC EXPANSION VALVES SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES High Superheat, Low Suction Pressure Moisture freezing and blocking valve Recover charge, install filter-drier, evacuate system, recharge Dirt or foreign material blocking valve Recover charge, install filter-drier, evacuate system, recharge Low refrigerant charge Correct the charge Vapor bubbles in liquid line Remove restriction in liquid line...
  • Page 50 THERMOSTATIC EXPANSION VALVES SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES Superheat is low to normal Unequal evaporator circuit loading Ensure air flow is equally distributed with low suction pressure through evaporator Check for blocked distributor tubes Low load or airflow entering Ensure blower is moving proper air evaporator coil Remove/Correct any air flow...

  • Page 51: Subcooling Calculation

    18.8 Subcooling Calculation TABLE 9 TEMPERATURE PRESSURE CHART 1. Measure the liquid pressure at the liquid line service valve. TEMP R-410A 2. Convert the liquid line pressure to saturated temperature. See Table 9. (Deg. F) PSIG 3. Measure the liquid line temperature at the liquid line service valve. -150 —...

  • Page 52: Wiring Diagrams

    19.0 WIRING DIAGRAMS FIGURE 11 WIRING DIAGRAM FOR 2, 3, & 4 TON...
  • Page 53 FIGURE 12 WIRING DIAGRAM FOR 5 TON...
  • Page 56 CM 1108...

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