Comfort PRL-series Скачать руководство пользователя страница 15 | Manualshive

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– 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. Always keep chips, steel wool, dirt, etc., out of the inside
when cleaning.

•

Assemble tubing part way into fitting. Apply flux all around the outside of the
tubing and push tubing into stop. This procedure will keep the flux from getting
inside the system.

•

Remove the cap and schrader core from service port to protect seals from heat
damage.

•

Use an appropriate heatsink material around the copper stub and the service
valves before applying heat.

•

IMPORTANT:

Do not braze any fitting with the TEV sensing bulb attached.

•

Braze the tubing between the outdoor unit and indoor coil. Flow dry nitrogen
into a service port and through the tubing while brazing.

•

After brazing – use an appropriate heatsink material to cool the joint and
remove any flux residue.

•

The service valves are not backseating valves. To open the valves, remove the
valve cap with an 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 DEMAND DEFROST CONTROL

The ICC has a demand defrost algorithm so a separate defrost control is not need-
ed. The ICC monitors the outdoor ambient temperature, outdoor coil temperature,
and the compressor run-time to determine when a defrost cycle is required.

8.1 Defrost Initiation

A defrost will be initiated when the three conditions below are satisfied:

1) The outdoor coil temperature is below 35°F.

2) The compressor has operated for at least 34 minutes with the outdoor coil tem-

perature below 35°F.

3) The defrost algorithm determines a defrost is required.

Additionally, a defrost will be initiated if six hours of accumulated compressor run-
time has elapsed without a defrost with the outdoor coil temperature below 35°F.

!

WARNING

DO NOT USE OXYGEN TO PURGE LINES OR PRESSURIZE SYSTEM FOR
LEAK TEST. OXYGEN REACTS VIOLENTLY WITH OIL, WHICH CAN
CAUSE AN EXPLOSION RESULTING IN SEVERE PERSONAL INJURY OR
DEATH.

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Содержание PRL-series

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 54: ...54 ...

Страница 55: ...55 ...

Страница 56: ...56 CM 1108 ...

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