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Service Manual  -  

HRG18xxS1P

508206-01

Issue 2140

Page 1 of 83

SERVICE MANUAL

HRG18xxS1P

(P) 508206-01

*P508206-01*

Table of Contents

Technical Specifications ..............................................2

Parts Arrangement.......................................................5

General ........................................................................8

Installation ...................................................................8

Refrigerant Piping ......................................................10

Electrical - Circuit Sizing and Wire Routing ...............19

Thermostat Control and Low Voltage Control Wiring 19

Outdoor Unitary Control.............................................23

Unit Operation ...........................................................25

Servicing Units Delivered Void of Charge..................29

Unit Start-Up ..............................................................29

System Operation and Service ..................................30

Configuring Unit .........................................................45

Maintenance ..............................................................46

Homeowner Information ............................................46

Wiring Diagram ..........................................................48

Unit Sequence of Operation ......................................49

Component Testing ....................................................53

This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to 

the potential for personal injury or death.

Electric shock hazard. 
Can cause injury or death. Before attempting 

to  perform  any  service  or  maintenance, 

turn  the  electrical  power  to  unit  OFF  at 

disconnect  switch(es).  Unit  may  have 

multiple power supplies.

 WARNING

As with any mechanical equipment, contact with sharp 

sheet  metal  edges  can  result  in  personal  injury. Take 

care  while  handling  this  equipment  and  wear  gloves 

and protective clothing.

 CAUTION

Improper  installation,  adjustment,  alteration,  service 

or maintenance can cause property damage, personal 

injury  or  loss  of  life.  Installation  and  service  must  be 

performed by a licensed professional HVAC installer (or 

equivalent), service agency or the gas supplier.

 WARNING

Summary of Contents for Century Comfort-Aire HRG18 S1P Series

Page 1: ...t symbol and should never be ignored When you see this symbol on labels or in manuals be alert to the potential for personal injury or death Electric shock hazard Can cause injury or death Before atte...

Page 2: ...3 2 8 1 3 VAR SPD 215 HRG1860S1P 208 230 60 1 197 253 33 7 50 24 7 2 8 1 3 VAR SPD 272 Note Weights listed are unit weights with packaging Factory charged for 15 feet of line set adjust per installati...

Page 3: ...n accordance with AHRI standard 270 2015 2 Rated in accordance with AHRI standard 275 2010 3 Based only on distance factor other factors may change this value such as Unit location reflective surfaces...

Page 4: ...y installed Prevents liquid migration to compressor in cold weather Sound Blanket All models Factory installed Lowers compressor sound level Short Cycle Protector All models Control Board Feature Prot...

Page 5: ...18xxS1P 508206 01 Issue 2140 Page 5 of 83 Parts Arrangement Figure 1 Parts Arrangement Control Panel Outdoor Control Board Inverter Contactor Ground Lug Vent Low Voltage Grommet Low Voltage Connection...

Page 6: ...Parts Arrangement 3 Ton Check Valve Low Pressure Switch Suction Pressure Transducer Accumulator Compressor Muffler TXV High Pressure Switch Crankcase Heater Thermostat Liquid Service Valve Vapor Serv...

Page 7: ...essure Switch Suction Pressure Transducer Compressor Muffler TXV High Pressure Switch Liquid Service Valve Vapor Service Valve Liquid Pressure Transducer Reversing Valve Compressor Temperature Limit N...

Page 8: ...ollow all safety codes Wear safety glasses and work gloves Use quenching cloth for brazing operations Have fire extinguisher available Read these instructions thoroughly and follow all warning or caut...

Page 9: ...ay from building not to exceed 1 4 per foot Figure 4 Slab Mounting Install on a Solid Level Mounting Pad The outdoor section is to be installed on a solid foundation This foundation should extend a mi...

Page 10: ...sharp bends Tubing can kink very easily and if this occurs the entire tube length will have to be replaced Extra care at this time will eliminate future service problems It is recommended that vertica...

Page 11: ...es listed in Table 3 Between 51 and 150 Linear Feet Crankcase heater and nonbleed port TXV factory installed No additional components required Vertical vapor riser must be sized to the vapor riser lis...

Page 12: ...G EQUALIZER LINE EXPANSION VALVE TEFLON RING STUB END TEFLON RING SENSING BULB LIQUID LINE ORIFICE HOUSING LIQUID LINE ASSEMBLY WITH BRASS NUT Figure 7 Remove Expansion Valve Uncased Coil Shown 1 On f...

Page 13: ...stem components including line set and indoor coil must be an AHRI match with the unit in order to fulfill unit warranty requirements Fire Explosion and Personal Safety hazard Failure to follow this w...

Page 14: ...wn Sensing bulb insulation is required if mounted external to the coil casing sensing bulb installation for bulb positioning STUB END TEFLON RING LIQUID LINE ASSEMBLY WITH BRASS NUT DISTRIBUTOR ASSEMB...

Page 15: ...must remain round Do not crimp end of the line Remove service cap and core from both the vapor and liquid line service ports 1 2 LIQUID LINE SERVICE VALVE SERVICE PORT CORE SERVICE PORT CAP SERVICE PO...

Page 16: ...SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE PREPARATION FOR NEXT STEP 7 WRAP SERVICE VALVES To help protect service valve seals during brazing wrap water saturated cloths around service valve...

Page 17: ...he high side of the manifold gauge set in order to pressurize the line set and the indoor unit E After a few minutes open one of the service valve ports and verify that the refrigerant added to the sy...

Page 18: ...deliver liquid refrigerant Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit G Perform the following Close manifold gauge valves Shut off HFC 41...

Page 19: ...d to control the outdoor unit R C W1 O and Y1 and Y1 is jumpered to Y2 in the outdoor unit Note that the published performance data is based upon the use of a two stage thermostat Refer to the HRG18 f...

Page 20: ...Suction Pressure Figure 12 Table 6 HRG18 Thermostat Control Options Install Thermostat Install room thermostat ordered separately on an inside wall approximately in the center of the conditioned area...

Page 21: ...100 30m 18 Temperature Rating 35 C Minimum More than 100 30m 16 Table 7 Conventional 24VAC Non Communicating Thermostat Wiring Route High Voltage and Ground Wires Any excess high voltage field wiring...

Page 22: ...DF TST Y1 O C W1 R G TC TO ACC2 ACC1 Y1 O DH C W2 W1 R G DS W2 O D SENSOR OPTIONAL FOR SINGLE STAGE OPERATION INSTALL A JUMPER BETWEEN Y1 TO Y2 ON THE OUTDOOR UNIT TERMINAL STRIP Figure 12 Conventiona...

Page 23: ...eration If the intended capacity for the application is 3 or 5 Ton skip this section The units are field convertible to 2 Ton or 4 Ton to efficiently perform for the required application If the intend...

Page 24: ...signal to initiate the Charge Mode A heating blower demand must also be provided to initiate high speed blower operation on the indoor unit The compressor and outdoor fan motor will begin to ramp up a...

Page 25: ...ompressor will be controlled in the variable capacity mode by varying the compressor capacity to obtain the target suction pressure set point If the heating or cooling demand remains after 20 minutes...

Page 26: ...cycle time the defrost accumulation time will be decreased by 30 minutes If the defrost accumulation time is significantly longer 200 or more of the target defrost cycle time or if the defrost termina...

Page 27: ...10 97 duty cycle 19 23 VDC peak C PWM fan common connection N A N A Fan PWM common P10 PSC Fan 1 4 QC 1 4 QC terminals Switched output for PSC outdoor fan control not used on HRG18 heat pumps N A Swit...

Page 28: ...utdoor coil temperature sensor not used 10K ohm resistor installed N A N A N A CHRG MODE Charge Mode function Can be used when charging checking charge pump down or checking unit operation Unit will r...

Page 29: ...d vapor line service valves to release the refrigerant charge contained in outdoor unit into the system 4 Replace the stem caps and tighten 5 Check voltage supply at the disconnect switch The voltage...

Page 30: ...Clear Alert Code Red LED Green LED N A N A ON OFF N A HRG1836S1P only Indicates inverter is operating normally N A N A ON ON N A HRG1860S1P only Indicates inverter is operating normally N A N A OFF OF...

Page 31: ...low 18VAC If this continues for 10 minutes the thermostat will turn off the applicable system component Automatically clears after voltage is detected as higher than 20VAC for two seconds or after pow...

Page 32: ...uperheat and sub cooling Automatically clears when error is corrected 423 40 4 flashes OFF Service Soon Service Urgent OD Inverter CT Circuit Fault The inverter has detected a circuit issue When this...

Page 33: ...ate have an inverter with updated software that includes compressor current slope logic to reduce the potential of alert code 427 instances from occurring during defrost Replace the inverter with the...

Page 34: ...n LED Three Flashes NOTE Inverter normal operations with no error code present is as follows Red LED is ON and Green LED is OFF Troubleshooting Suggestions Check wire connections U V and W at inverter...

Page 35: ...ervice Urgent OD Inverter DC Link High Voltage The inverter has detected a DC link high voltage condition Error occurs when the DC link capacitor voltage is greater than 480 VDC If condition is detect...

Page 36: ...This alert code may be triggered by the inverter or the Comfort Aire or Century variable capacity outdoor inverter controlled unit Comfort Aire or Century outdoor control may trigger an this alert cod...

Page 37: ...ct power to outdoor unit and restart Table 12 Alert Codes and Troubleshooting Outdoor control has lost communications with the inverter continuously during a single thermostat call and one hour period...

Page 38: ...eshooting procedures Inverter flash code 62 The sequence is Red LED Six Flashes Green LED Two Flashes NOTE Inverter normal operations with no error code present is as follows Red LED is ON and Green L...

Page 39: ...er has detected the error moderate condition After three minutes the inverter will reset and the compressor will resume operation If the error condition occurs 10 times within a 60 minute rolling time...

Page 40: ...ction for a brief period of time and to reduce the heat sink temperature and will then resume normal operation This may occur at high outdoor temperatures above 110 F for brief periods of time 3 4 min...

Page 41: ...4 The sequence is Red LED One Flash Green LED Four Flashes NOTE Inverter normal operations with no error code present is as follows Red LED is ON and green LED is OFF Automatically clears when the con...

Page 42: ...o characters If the unit code cannot be determined three bars appear THROUGH OR These are just examples of firmware version unit type unit nominal capacity and unit codes UNIT CODE UNIT TYPE SIZE AND...

Page 43: ...300 sec 5 min Cooling Capacity Shows cooling stage C1 or C2 operating if non communicating Cooling compressor capacity 1second on 0 5 second off followed by ambient temperature Non Communicating ther...

Page 44: ...horizontal bars display Release button outdoor fan cycles OFF A A in the display string represents the ambient temperature in F at the sensor on the outdoor unit Control can be in Idle or demand mode...

Page 45: ...the display string must be repeated Yes No NOTE Either the sequence will repeat 5 times and if a selection is not made the control will return to idle mode NOT SELECTED SELECTED Configuring Unit Selec...

Page 46: ...s by movement of the air Clogged condenser coils will lower the efficiency of your unit and could cause damage to the condenser Periodically debris should be brushed from the condenser coils Use a sof...

Page 47: ...trol is a priority The ON or CONT mode provides continuous indoor blower operation regardless of whether the compressor or auxiliary heat are operating This mode is required when constant air circulat...

Page 48: ...Service Manual HRG18xxS1P 508206 01 Issue 2140 Page 48 of 83 Figure 20 Wiring Diagram Wiring Diagram...

Page 49: ...om idle mode Outdoor Control 1 Sends a demand to the compressor inverter to start and run the compressor up to the requested pumping capacity Frequency in hertz 2 On HRG18 units output signal is provi...

Page 50: ...15 F OR BELOW SWITCH IS CLOSED OR 3 5 STRIKE COUNTER REACHES 5 WITHIN A SINGLE Y1 DEMAND LOW PRESSURE LOCKOUT LED ALERT CODE OR CRITICAL ALERT 411 DISPLAYED SERVICE REQUIRED2 LED ALERT CODE OR MODERA...

Page 51: ...NTER REACHES 5 WITHIN A SINGLE Y1 DEMAND HIGH PRESSURE SWITCH S4 LOCKOUT LED ALERT CODE OR CRITICAL ALERT 413 CLEARED SERVICE REQUIRED2 LED ALERT CODE OR MODERATE ALERT 412 DISPLAYED NORMAL OPERATION...

Page 52: ...ROST CYCLE TIME FROST ACCUMULATION TIME INCREASED BY 30 MIN DEFROST CYCLE WILL RUN AND THE TIME IS COMPARED TO TARGET DEFROST CYCLE TIME 120S 125S 130S 135S DEFROST CYCLE TIME WILL BE MEASURED UNTIL C...

Page 53: ...and LPS terminals respectively NOTE The HRG18 does not have a low pressure switch and LPS terminals are not jumpered The unit has a suction pressure transducer that emulates the low pressure switch w...

Page 54: ...ut from transducer to Pin 3 Black GND should read 0 5 to 4 5 VDC and will vary depending on suction pressure measured See Table 16 VDC Figure 26 Suction Pressure Transducer Voltage Suction Pressure PS...

Page 55: ...VDC Figure 27 Liquid Pressure Transducer Voltage Liquid Pressure PSIG DC Voltage Output Pin 2 to Pin 3 Liquid Pressure PSIG DC Voltage Output Pin 2 to Pin 3 0 0 50 260 2 58 10 0 58 270 2 66 20 0 66 2...

Page 56: ...Switch Strikes Lockout The high pressure switch has opened five times during one cooling demand Thermostat will shut down the outdoor unit Open high pressure switch error count reached five strikes Ch...

Page 57: ...red remove the compressor through the top of the unit Removal through the access panel is not possible ELECTRICAL CONNECTION PLUG LOCATION NOT SHOWN DISCHARGE SUCTION EQUALIZATION VALVE HRG18 ROTARY C...

Page 58: ...start unloaded The 240 VAC solenoid coil is controlled by the inverter The solenoid coil is powered when the compressor is off to equalize the pressure and is de energized when the compressor is opera...

Page 59: ...rs when compressor peak phase current is greater than 28 amps Inverter will issue inverter code 14 first and slow down to try to reduce the current If the current remains high outdoor unit will stop c...

Page 60: ...brief period of time and to reduce the heat sink temperature and will then resume normal operation This may occur at high outdoor temperatures above 110 F for brief periods of time 3 4 minutes and is...

Page 61: ...r speed by 4 Hz and slow the compressor ramp up speed to the requested compressor demand speed capacity This is normal and expected operation of the inverter to control the inverter within design para...

Page 62: ...rises above 70 F the thermostat opens which results in the heater being de energized Figure 31 Belly Band Crankcase Heater Thermostat Belly Band Crankcase Heater 240VAC 40 Watts Crankcase Heater Ther...

Page 63: ...Line Filter Drier Rotary Compressor Models Only The HRG1836S1P units have a rotary compressor and have a factory installed suction line filter drier installed in the suction line Liquid drier is not r...

Page 64: ...the compressor casing This switch senses the compressor casing temperature and opens at 239 257 F to shut off compressor operation The auto reset switch closes when the compressor casing temperature...

Page 65: ...sub cooling Automatically clears when error is corrected 442 Service Urgent OD Compressor Top Cap Switch Strikes Lockout The top cap switch has opened five times within one hour As a result the outdo...

Page 66: ...he button and the outdoor fan will cycle off Units with ECM Motor 1 With the unit running check for 230VAC at the red outdoor fan motor wires at the contactor If no voltage is present check main power...

Page 67: ...yed on the communicating thermostat GF Gas Furnace AH Air Handler ID Indoor unit GF or AH HP Heat Pump AC Air Conditioner OD Outdoor Unit AC or HP ZA Zone system and TS Thermostat Alert Code Inverter...

Page 68: ...will display are E182 error code if the sensor reads open or shorted for 24 hours Cooling operation is allowed with this fault Liquid Line Temperature Sensor RT36 Liquid line temperature is read by th...

Page 69: ...e value that is not within the range shown in figure 49 may be performing as designed However if a shorted or open circuit is detected then the sensor may be faulty and the sensor harness will need to...

Page 70: ...0 118126 57 5 16345 22 1 43468 10 6 120600 Table 22 Ambient and Liquid Line Sensors Temperature Resistance Range 508206 01 Issue 2140 Page 70 of 83 enheit Resistance enheit Resistance enheit Resistanc...

Page 71: ...d a problem with the outdoor sensor in the outdoor unit or the optional outdoor sensor connected to the indoor unit In normal operation after system component control recognizes sensors the alert code...

Page 72: ...lockout Inverter will flash codes 12 to 14 and 53 NOTE These inverter codes do not count towards this lockout condition To clear disconnect power to outdoor control and restart 427 21 2 flashes 1 flas...

Page 73: ...ll display a moderate code If condition is detected outdoor unit will stop compressor and fan moderate condition An anti short cycle timer is initiated If condition occurs 10 times within a 60 consecu...

Page 74: ...ED Six Flashes NOTE Inverter normal operations with no error code present is as follows Red LED is ON and Green LED is OFF Check refrigerant Replace outdoor control board Replace inverter To clear dis...

Page 75: ...ill flash code 28 Refer to the unit service documentation for detailed troubleshooting procedures Inverter flash code 28 The sequence is Red LED Two Flashes Green LED Eight Flashes NOTE Inverter norma...

Page 76: ...e triggered by the inverter or the Comfort Aire or Century variable capacity outdoor inverter controlled unit Comfort Aire or Century outdoor control may trigger an this alert code if the inverter red...

Page 77: ...ical alert code 434 reset the system by cycling the outdoor unit power off and back on Then cycle the indoor power off 24VAC to the Comfort Aire or Century outdoor control and then back on If this con...

Page 78: ...Inverter flash code 62 The sequence is Red LED Six Flashes Green LED Two Flashes NOTE Inverter normal operations with no error code present is as follows Red LED is ON and Green LED is OFF Moderate co...

Page 79: ...rror moderate condition After three minutes the inverter will reset and the compressor will resume operation If the error condition occurs 10 times within a 60 minute rolling time period the outdoor u...

Page 80: ...iod of time and to reduce the heat sink temperature and will then resume normal operation This may occur at high outdoor temperatures above 110 F for brief periods of time 3 4 minutes and is normal an...

Page 81: ...or to operate within design parameters Alert code 441 typically occurs at startup as the compressor current increases rapidly during startup The inverter will reduce the compressor speed by 4 Hz and s...

Page 82: ...Z C M CG24P A B C 4P C M CG24T A B C 4P C M CG3036P A B C 4P C M CG3036T A B C 4P C M CG30P A B C 5P C M CG30T A B C 5P 16 4 1 LB 2 OZ HEATING 5 F COOLING 1 F HEATING 5 F COOLING 1 F C M CG48P C D CP...

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