Comfort PRL-series Installation Instructions Manual Download | Manualshive

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92-20522-63-02

SUPERSEDES 92-20522-63-01

TWO-STAGE HEAT PUMP OUTDOOR UNITS

(-)PRL-JEC 16 SEER EQUIPPED WITH THE

COMFORT CONTROL

2

SYSTEM™

INSTALLATION INSTRUCTIONS

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!

!

DO NOT DESTROY THIS MANUAL

PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN

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.

WARNING

!

[ ] INDICATES METRIC CONVERSIONS

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2
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Summary of Contents for PRL-series

Page 1: ...E PLACE FOR FUTURE REFERENCE BY A SERVICEMAN 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 FI...

Page 2: ...11 1 Evacuation Procedure 17 12 0 CONDENSING UNITS EQUIPPED WITH COMFORT CONTROL2 SYSTEM 18 12 1 Control Description 18 12 2 Comfort Control2 Control Wiring 20 12 3 Comfort Control2 ICC Control Operation 20 12 4 Active Compressor Protection Mode 22 12 5 Test and Fault Recall Modes 24 12 6 ICC Diagnostic Codes 26 29 12 7 Conventional 24VAC Thermostat Control Wiring 29 12 8 Typical Thermostat Wiring...

Page 3: ...VICES MAY ADVERSELY AFFECT THE OPERATION OF THE AIR CONDITIONER AND MAY ALSO ENDANGER LIFE AND PROPERTY THE MANUFACTURER DISCLAIMS ANY RESPONSIBILITY FOR SUCH LOSS OR INJURY RESULTING FROM THE USE OF SUCH UNAUTHORIZED COMPONENTS ACCESSORIES OR DEVICES WARNING DISCONNECT ALL POWER TO UNIT BEFORE STARTING MAINTENANCE FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR ...

Page 4: ... PRESSURES USE APPROPRIATE CARE WHEN USING THIS REFRIGER ANT FAILURE TO EXERCISE CARE MAY RESULT IN EQUIPMENT DAM AGE OR PERSONAL INJURY CAUTION THE COMPRESSOR HAS AN INTERNAL OVERLOAD PROTECTOR UNDER SOME CONDITIONS IT CAN TAKE UP TO 2 HOURS FOR THIS OVERLOAD TO RESET MAKE SURE OVERLOAD HAS HAD TIME TO RESET BEFORE CONDEMNING THE COMPRESSOR CAUTION Only use evaporators approved for use on R 410A ...

Page 5: ...oling heat gain calculation makes similar measurements and determines the amount of heat needed to be removed A heat gain calculation also calculates the extra heat load caused by sunlight and by humidity removal These factors must be considered before selecting a heat pump system to provide year round comfort The Air Conditioning Contractors of America ACCA J Manual method of load calculation is ...

Page 6: ... 22 mm HIGH VOLTAGE CONNECTION 111 32 34 mm LIQUID LINE CONNECTION SERVICE ACCESS TO ELECTRICAL VALVES ALLOW 24 610 mm CLEARANCE ONE SIDE 27 8 73 mm DIA ACCESSORY KNOCKOUTS VAPOR LINE CONNECTION HIGH PRESSURE CONTROL MANUAL RESET FIELD INSTALLED ACCESSORY A 00003 DIMENSIONAL DATA ALLOW 24 610 mm SERVICE ACCESS CLEARANCE AIR INLETS LOUVERS ALLOW 6 152 mm MIN CLEARANCE 3 SIDES ACCESS PANEL AIR DISCH...

Page 7: ...ollow the manufac turer s refrigerant charging and airflow instructions Failure to confirm proper charge and airflow may reduce energy efficiency and shorten equipment life 3 0 LOCATING UNIT 3 1 Corrosive Environment The metal parts of this unit may be subject to rust or deterioration if exposed to a corrosive environment This oxidation could shorten the equipment s useful life Corrosive elements ...

Page 8: ...cause the cabinet to ice over prematurely and prevent heat pump operation requiring backup heat which generally results in less economical operation Closely follow clearance recommendations on Page 6 o 24 to the service panel access o 60 above heat pump fan discharge unit top to prevent recirculation o 6 to heat pump coil grille air inlets 3 4 For Units With Space Limitations FOR CONDENSERS WITH S...

Page 9: ...ed see Figure 3 STEP 4 Drill four pilot holes in pad ensuring that the hole is at least 1 4 deeper than the concrete screw being used STEP 5 Center basepan over pre drilled holes and insert concrete screws STEP 6 Tighten concrete screws NOTE Do not over tighten the concrete screws Doing so can weaken the integrity of the concrete screw and cause it to break STEP 7 Finish unit assembly per unit s i...

Page 10: ...C 125 Pressure The pressure of R 410A is approximately 60 1 6 times greater than R 22 Recovery and recycle equipment pumps hoses and the like need to have design pressure ratings appropriate for R 410A Manifold sets need to range up to 800 psig high side and 250 psig low side with a 550 psig low side retard Hoses need to have a service pressure rating of 800 psig Recovery cylinders need to have a ...

Page 11: ...EMENT UNITS To prevent failure of a new condensing unit the existing evaporator tubing system must be correctly sized and cleaned or replaced Care must be exercised that the expansion device is not plugged For new and replacement units a liquid line filter drier should be installed and refrigerant tubing should be properly sized Test the oil for acid If positive a suction line filter drier is mand...

Page 12: ...s 150 feet Always use the shortest length possible with a minimum number of bends Additional compressor oil is not required for any length up to 150 feet NOTE Excessively long refrigerant lines cause loss of equipment capacity TABLE 3 VAPOR LINE CAPACITY MULTIPLIER 12 024 PRL Unit Vapor Line Connection Size inches I D mm Vapor Line Run Feet m 3 4 19 05 I D Sweat 7 8 22 23 I D Sweat 7 8 22 23 I D S...

Page 13: ... 70 25 7 62 46 14 02 45 13 72 44 13 41 43 13 11 42 12 80 5 16 7 93 25 7 62 17 5 18 N A N A N A N A 048 3 8 9 53 3 8 9 52 25 7 62 47 14 33 39 11 89 31 9 45 23 7 01 16 4 88 1 2 12 70 25 7 62 50 15 24 58 17 68 56 17 07 54 16 46 53 16 15 3 8 9 52 25 7 62 18 5 49 11 3 35 N A N A N A 060 3 8 9 53 1 2 12 70 25 7 62 29 8 84 27 8 23 26 7 93 25 7 62 23 7 01 25 7 62 50 15 24 75 22 86 100 30 48 125 38 1 150 4...

Page 14: ... permanent hangers Line must be adequately supported The vapor line must be insulated to prevent dripping sweating and prevent performance losses Armaflex and Rubatex are satisfactory insulations for this purpose Use 1 2 minimum insulation thickness additional insulation may be required for long runs Check Table 3 for the correct vapor line size Check Table 4 for the correct liq uid line size 7 5 ...

Page 15: ...n adjustable wrench Insert a 3 16 or 5 16 hex wrench into the stem Back out counterclockwise Replace the valve cap finger tight then tighten an additional 1 2 hex flat for a metal to metal seal 7 6 Leak Testing Pressurize line set and coil through service fittings with dry nitrogen to 150 PSIG maximum Leak test all joints using liquid detergent If a leak is found recover pressure and repair 8 0 DE...

Page 16: ...Demand Defrost Set the indoor thermostat select switch to heat and initiate a call for heat Press SW2 to put the unit into defrost If the unit goes into defrost and comes back out of defrost the indication is that the control is working properly 9 0 COMPRESSOR CRANKCASE HEAT CCH CCH is standard on these models due to refrigerant migration during the off cycle that can result in a noisy start up Cr...

Page 17: ...lly reacts with the refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids These attack motor windings and parts causing breakdown After the system has been leak checked and proven sealed connect the vacuum pump and evacuate system to 500 microns The vacuum pump must be connected to both the high and low sides of the system through adequate connections Use the largest size conne...

Page 18: ... 8 AWG 40 in lbs 10 14 AWG 35 in lbs Check wire terminations annually Compressor Control K2 Sealed single pole compressor relay switch with optical feedback feature arc detection FIGURE 4 ICC BOARD COMPRESSOR WIRING CONNECTOR O D FAN OFM RELAY COMPRESSOR CONTROL K2 ICC INTEGRATED COMPRESSOR CONTROL TEST BUTTON 7 SEGMENT LED AMBIENT DEFROST CONTROL DEFROST SENSOR SW2 BUTTON RED LED Y1 LOW VOLT FUSE...

Page 19: ...ontrol is factory installed High pressure control is an automatic resetting device Ambient Temperature Sensor included with all applications Included with all applications TEST and SW2 Buttons TEST and SW2 buttons used to enter Test and Fault Recall Mode Memory Card The memory card stores all unit information The unit information is called shared data The shared data is all the information needed ...

Page 20: ... Op pe er ra at ti io on n Y Y1 1 L LE ED D If a command for compressor operation is received by the ICC first stage second stage cooling or first stage second stage heating the red Y1 LED will illuminate The ICC has an on off fan delay of one 1 second for each stage of heating or cooling The ICC ignores the low pressure control for the first 90 seconds of compressor operation On heat pumps the IC...

Page 21: ...on When the ICC receives a command for second heating operation h2 is displayed on the 7 segment LEDs h2 indicates second stage heating operation 5 Defrost Operation When the ICC starts a defrost cycle a lower case d is displ on the 7 segment LEDs Lower case d indicates defrost operation in heating mode 3 minute Anti short Cycle Timer H 3 Upper case C indicates second stage cooling operation 3 Fir...

Page 22: ...keep it from continuing to operate and flash a L on the dual 7 segment LEDs followed by a 21 I IM MP PO OR RT TA AN NT T This mode of active protection must be manually reset A Ac ct ti iv ve e P Pr ro ot te ec ct ti io on n w wi it th h s so of ft t l lo oc ck ko ou ut t If the LPC opens three 3 times for the same command for heating and the out door ambient temperature is below 5F the ICC will l...

Page 23: ...compressor to keep it from continuing to operate and flash a L on the 7 segment LEDs followed by a 4 IMPORTANT This mode of active protection must be manually deactivated 4 Open Start Circuit Lockout 6 If the HPC opens three 3 times during the same command 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 ...

Page 24: ...t without a command for unit operation If the 3 minute anti short cycle timer or 30 second minimum run timer is active a flashing c C h1 or h2 is displayed on the 7 segment LEDs and a command for unit operation is present TEST mode causes 1 A t to display momentarily on the 7 segment display Lower case t 2 The compressor will start 3 The display will change to a steady c C h1 or h2 to show the cur...

Page 25: ...red data for this unit The memory card is attached to the control box with a tether The tether has an identifi cation tag that can be used to identify the memory card For the system data faults d1 through d8 reference the label on the memory card tether 9 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...

Page 26: ...m run timer 30 seconds active The unit has received a command for second stage cooling during an active anti short cycle timer or minimum run timer Wait unit timer has expired or press the TEST button to reset timer h1 First Stage Heat Pump Unit has received a command for first stage heat pump Normal operation FLASHING h1 Anti short cycle timer 3 minutes or Minimum run timer 30 seconds active The ...

Page 27: ...as received a command for unit operation but no current is present in the start and run circuits The ICC will attempt to restart the unit every five 5 minutes for four 4 attempts After that the ICC will attempt a restart every twenty 20 minutes for up to four 4 hours Check for damaged miswired or wrong run capacitor Check for broken wires loose connectors or miswired compressor Check compressor wi...

Page 28: ...cts the LPC is open Note The low pressure control is ignored for the first 90 seconds of compressor operation Unit has low refrigerant charge Indoor coil is frozen cooling mode Dirty indoor coil or filter cooling mode Indoor blower is not running cooling mode Outdoor coil is frozen heating mode Outdoor fan is not running heating mode Expansion valve is not operating correctly FLASHING L21 Active P...

Page 29: ... trips have occurred and the average run time for each trip is less than 15 seconds Bad run capacitor Low line voltage Excessive refrigerant in compressor Seized bearings in compressor 05 Open Circuit Compressor will not Run The ICC has received a command for unit operation but no current is present in the start and run circuits The ICC will attempt to restart the unit every five 5 minutes for fou...

Page 30: ...p Outdoor Unit Y2 C R B Y2 Field Installed Line Voltage WIRING INFORMATION Factory Standard ODD R Y1 Y2 G W2 R Y1 C L D Y Y BL BL R BR W R PR DHM L FIGURE 9 PRL HEAT PUMP WITH ELECTRIC HEAT USING A TWO STAGE THERMOSTAT WITH DEHUMIDIFICATION AND A MALFUNCTION LIGHT 12 8 Typical Non Communicating Thermostat Wiring Diagrams WIRE COLOR CODE BK BLACK G GREEN PR PURPLE Y YELLOW BR BROWN GY GRAY R RED BL...

Page 31: ...es first stage heating operation 4 Second Stage Heating Operation When the ICC receives a call for second stage heating operation h2 is displayed on the 7 segment LEDs 2 Zero 0 displayed The unit is in standby Call for Compressor Operation Y1 LED If a call for compressor operation is received by the ICC first stage second stage cooling or first stage second stage heating the red Y1 LED will illumi...

Page 32: ...2 Zero 0 displayed The unit is in standby Call for Compressor Operation Y1 LED If a call for compressor operation is received by the ICC first stage second stage cooling or first stage second stage heating the red Y1 LED will illuminate The ICC has an on off fan delay of one 1 second for each stage of heating or cooling The ICC ignores the lower pressure control for the first 90 seconds of compres...

Page 33: ...same call for heating and the outdoor ambient temperature is below 5F 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 21 Once the outdoor ambient rises above 5F the ICC will clear active pro tection automatically I IM MP PO OR RT TA AN NT T This mode of active protection will automatically deactivate once the outdoor ...

Page 34: ...Lockout The ICC will display a flashing L followed by a flashing 7 when an open start circuit condition occurs Active Protection Code L7 Compressor open run circuit 6 Active Protection Code L4 Locked rotor If the ICC detects the compressor has run less than 15 seconds for four 4 consecutive starts during the same call for unit operation the ICC will lockout the compressor to keep it from continuin...

Page 35: ...e dual 7 segment LEDs Fault Recall Mode TEST and SW2 Buttons Enter FAULT RECALL mode by pressing the TEST and SW2 buttons at the same tim with insulated probes for one 1 second and release When entering and exiting FAULT RECALL mode the top and bottom segments of the segment LEDs will illuminate Fault Recall Mode the top and bottom segments illuminated When entering FAULT RECALL mode the ICC will ...

Page 36: ...e TEST and SW2 buttons at the same time with insulated probes for one 1 second and release When entering and exiting FAULT RECALL mode the top and bottom segments of the 7 segment LEDs will illuminate Fault Recall Mode the top and bottom segments illuminated When entering FAULT RECALL mode the ICC will automatically scroll through stored faults on the 7 segment LEDs Each fault is displayed one tim...

Page 37: ...d wire to the contactor terminals 13 2 Grounding A grounding lug is provided near the contactor for a ground wire 13 3 Control Wiring If the low voltage control wiring is run in conduit with the power supply Class I insu lation is required Class II insulation is required if run separate Low voltage wiring may be run through the insulated bushing provided in the 7 8 hole in the base panel up to and...

Page 38: ...s the possibility of high humidity problems Low indoor airflow reduces total capacity and causes coil icing Serious harm can be done to the compressor by low airflow such as that caused by refrigerant flooding Heat pump systems require a specified airflow Each ton of cooling requires between 340 and 450 cubic feet of air per minute CFM Duct design and construction should be carefully done System p...

Page 39: ...id and suction pressures at the ports on the liquid and suction valves If refrigerant lines are sized using the nameplate charge the correct liquid pressure is found at the intersection of the suction pressure and the outdoor ambient 1 Remove refrigerant charge if the liquid pressure is above the chart value 2 Add refrigerant charge if the liquid pressure is below the chart value 16 3 Charging By ...

Page 40: ...ch follow are not intended to be an answer to all problems but only to guide the technician s troubleshooting Through a series of yes and no answers follow the logical path to a likely conclusion A novice technician should use these charts like a road map Remember that the chart should clarify a logical path to the solution 18 1 Serial Communicating System Initial Startup Connect the system There ...

Page 41: ...s information that allows the unit to operate correctly When a control board requires replacement it is important that the replacement board gets the shared data from the old control The primary way the replacement control gets this information is by the memory card that should be installed on the old control Remove the memory card from the old control but leave it attached to the unit by the plas...

Page 42: ...ault history and refer to Diagnostic Chart Note For solid comm LED check comm wiring term bus switches at ICC and AH ctrls Refer to panel cover documentation for Fault Code Troubleshooting Check fault history for other faults Check control voltage R and C to control Waiting for Anti S C Delay to clear Thermostat call For cooling no cooling No Yes Y1 LED lit No call received 24V Systems Check therm...

Page 43: ...Recirculation of Inoperative Compressor Inoperative Indoor Blower Outdoor Air Valves Non condensibles Outdoor Check Valve Low on Charge Closed Higher than Ambient Restricted Indoor Air Entering Outdoor Coil Metering Device Restricted Indoor Wrong Outdoor Fan Rotation Metering Device Restriction in System Restricted Recirculation of Filter Drier Indoor Air Wrong Indoor Blower Rotation Inadequate Du...

Page 44: ... 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 During Defrost in Defrost Loose Defrost Sensor Check Coil Sensor Connector 44 ...

Page 45: ...weat Low indoor airflow Increase speed of blower or reduce restriction replace air filter High head low vapor pressures Restriction in liquid line expansion device or filter drier Remove or replace defective component Flowcheck piston size too small Change to correct size piston Incorrect capillary tubes Change coil assembly High head high or normal vapor Dirty outdoor coil Clean coil pressure Coo...

Page 46: ...is High voltage Power company problem Have problem corrected High head pressure Overcharge Check system charge Dirty heat pump coil Clean coil Faulty or wrong size Replace fan motor heat pump fan motor Faulty fan blade Replace fan blade or wrong rotation Replace with correct rotation motor Recirculation of air Correct installation Additional Heat Source Check for dryer vent near unit Check for rec...

Page 47: ...gh pressure switch Low pressure switch Ambient thermostat Solid state protection control or internal thermal sensors Compressor timed off on control or interlock No voltage on line side Blown fuses or tripped circuit breaker Check for short in wiring or unit of compressor contactor Improper wiring Re check wiring diagram Improper voltage High voltage Wrong unit Power supply problem Low voltage Wro...

Page 48: ...out of calibration Customer misuse FLOODED STARTS SYMPTOMS POSSIBLE CAUSES CHECK OR REMEDIES Liquid in the compressor shell Faulty or missing crankcase heater Replace crankcase heater Too much liquid in system Incorrect piping Check Piping guidelines Overcharge Check and adjust charge SLUGGING SYMPTOMS POSSIBLE CAUSES CHECK OR REMEDIES On start up Incorrect piping Review pipe size guidelines TEV h...

Page 49: ... clockwise superheat settings Valve feeds too much refrigerant Moisture causing valve to stick open Recover refrigerant replace filter with low superheat and higher than drier evacuate system and then nor mal suction pressure recharge Dirt or foreign material causing Recover refrigerant replace filter valve to stick open drier evacuate system and recharge TEV seat leak A gurgling or hissing Replac...

Page 50: ...er refrigerant or refrigerant oil flowing position around the circumference of through suction line the suction line Unequal refrigerant flow through Ensure sensing bulb is located evaporator circuits properly Check for blocked distributor tubes Improper superheat adjustment Replace TEV or adjust superheat only possible with TEV having superheat adjustment Moisture freezing and partially Recover r...

Page 51: ...rcharge Low Low High Low Low Liquid Restriction Drier Low Low High High Low Low Evaporator Airflow Low Low Low Low Low Dirty Heat Pump High High Low Low High Low Outside Ambient Temperature Low Low High High Low Inefficient Compressor Low High High High Low TXV Feeler Bulb Charge Lost Low Low High High Low Poorly Insulated Sensing Bulb High High Low Low High SYSTEM PROBLEM INDICATORS TABLE 9 TEMPE...

Page 52: ...FIGURE 11 WIRING DIAGRAM FOR 2 3 4 TON 19 0 WIRING DIAGRAMS 52 ...

Page 53: ...FIGURE 12 WIRING DIAGRAM FOR 5 TON 53 ...

Page 54: ...54 ...

Page 55: ...55 ...

Page 56: ...56 CM 1108 ...

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