187B (2 -- 5 TONS)
180B (3 TON TROPHY)
EVOLUTIONt SERIES 2--STAGE AIR CONDITIONER
R
WITH PURON REFRIGERANT
Installation Instructions
Indoor Thermostat Control Options
SAFETY CONSIDERATIONS
Standard
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Evolution
Control
2 --- s t a g e
Model
Thermostat
187B / 180B
Yes
Yes
INSTALLATION RECOMMENDATIONS
NOTE: In some cases noise in the living area has been traced to
gas pulsations from improper installation of equipment.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes and
current editions of the National Electrical Code ( NEC ) NFPA 70.
In Canada, refer to current editions of the Canadian electrical code
CSA 22.1.
1. Locate unit away from windows, patios, decks, etc. where
unit operation sound may disturb customer.
2. Ensure that vapor and liquid tube diameters are appropriate
for unit capacity.
3. Run refrigerant tubes as directly as possible by avoiding un-
necessary turns and bends.
!
!
Recognize safety information. This is the safety--alert symbol
4. Leave some slack between structure and unit to absorb vi-
bration.
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand
these signal words; DANGER, WARNING, and CAUTION. These
words are used with the safety--alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury
or death. WARNING signifies hazards which could result in
personal injury or death. CAUTION is used to identify unsafe
practices which would result in minor personal injury or product
and property damage. NOTE is used to highlight suggestions
which will result in enhanced installation, reliability, or operation.
5. When passing refrigerant tubes through the wall, seal open-
ing with RTV or other pliable silicon--based caulk. (See Fig.
1.)
6. Avoid direct tubing contact with water pipes, duct work,
floor joists, wall studs, floors, and walls.
7. Do not suspend refrigerant tubing from joists and studs with
a rigid wire or strap which comes in direct contact with
tubing.(See Fig. 1.)
8. Ensure that tubing insulation is pliable and completely sur-
rounds vapor tube.
!
WARNING
ELECTRICAL SHOCK HAZARD
9. When necessary, use hanger straps which are 1 in. (25.4
mm) wide and conform to shape of tubing insulation. (See
Fig. 1.)
Failure to follow this warning could result in personal injury
or death.
10. Isolate hanger straps from insulation by using metal sleeves
bent to conform to shape of insulation.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position and
install a lockout tag. There may be more than 1 disconnect
switch. Lock out and tag switch with a suitable warning label.
NOTE:Avoid contact between tubing and structure
OUTDOOR WALL
INDOOR WALL
CAULK
LIQUID TUBE
!
CAUTION
VAPOR TUBE
JOIST
CUT HAZARD
INSULATION
THROUGH THE WALL
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing and gloves when
handling parts.
HANGER STRAP
(AROUND VAPORTUBE ONLY)
INSULATION
VAPOR TUBE
1” (25.4 mm) MIN.
LIQUID TUBE
SUSPENSION
A94026
Fig. 1 -- Piping Installation
Table 1 – Accessory Usage
REQUIRED FOR
L O W --- A M B I E N T C O O L I N G
APPLICATIONS
REQUIRED FOR SEA COAST
APPLICATIONS
(Within 2 miles/3.22 km)
REQUIRED FOR LONG LINE
APPLICATIONS*
ACCESSORY
(Below 55°F/12.8_C)
Compressor Start Assist Kit
Crankcase Heater
No
Standard
Yes
Standard
No
Standard
Standard with Evolutiont Control
(Low Ambient not allowed with
non---communicating thermostat)
No
Standard with Evolution Control
(Low ambient not allowed with
non---communicating thermostat)
Evaporator Freeze Protection
Liquid---Line Solenoid Valve
Low---Ambient Control
No
No
No
No
No
No
Puron Refrigerant Balance Port Hard---
ShutOff TXV
Yes{
Yes{
Yes{
Support Feet
Recommended
No
Recommended
Standard with Evolution Control
(Low Ambient not allowed with
non---communicating thermostat)
Winter Start Control
No
No
*
For tubing set lengths between 80 and 200 ft. (24.38 and 60.96 m) horizontal or 35 ft. (10.7 m) vertical differential (total equivalent length), refer to the Long
Line Guideline—Air Conditioners and Heat Pumps using Puron® Refrigerant.
{
Required on all indoor units. Standard on all new Puron refrigerant fan coils and furnace coils.
Table 2 – Refrigerant Connections and Recommended Liquid
and Vapor Tube Diameters (In.)
Outdoor Unit Connected to Factory Approved Indoor
Unit
Outdoor unit contains correct system refrigerant charge for
operation with factory approved AHRI rated indoor unit when
connected by 15 ft. (4.57 m) of field--supplied or factory--accessory
tubing, and factory supplied filter drier. Check refrigerant charge
for maximum efficiency.
NOTE: If the indoor furnace coil width is more than the furnace
casing width, refer to the indoor coil Installation Instructions for
transition requirements.
LIQUID
RATED VAPOR*
Connection
& Max. Tube
Diameter
UNIT SIZE
Connection
Tube
Diameter
Diameter
024
036
048
060
3/8
3/8
3/8
3/8
3/4
7/8
7/8
7/8
3/4
7/8
1-1/8
1-1/8
*
Units are rated with 25 ft. (7.6 m) of lineset. See Product Data sheet for
performance data when using different size and length linesets.
Notes:
1. Do not apply capillary tube or fixed orifice indoor coils to these units.
!
2. For Tubing Set lengths between 80 and 200 ft. (24.38 and 60.96 m)
horizontal or 35 ft. (10.7 m) vertical differential 250 ft. (76.2 m) Total
Equivalent Length), refer to the Residential Piping and Longline Guide
line--- Air Conditioners and Heat Pumps using Puron refrigerant.
WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury
or equipment damage.
3. For alternate liquid line options on 18---42 size units, see Product Data or
Residential Piping and Application Guideline
Install Liquid-Line Filter Drier Indoor
PuronR refrigerant systems operate at higher pressures than
standard R--22 systems. Do not use R--22 service equipment
or components on PuronR refrigerant equipment.
!
CAUTION
Refrigerant Tubing Connection Outdoor
Connect vapor and liquid tubes to fittings on vapor and liquid
service valves (see Table 2.) Use refrigerant grade tubing.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Sweat Connection
1. Installation of filter drier in liquid line is required.
2. Filter drier must be wrapped in a heat--sinking material
such as a wet cloth while brazing.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Service valves must be wrapped in a heat--sinking material
such as a wet cloth while brazing.
Use refrigeration grade tubing. Service valves are closed from
factory and ready for brazing. After wrapping service valve with a
wet cloth, braze sweat connections using industry accepted
methods and materials. Consult local code requirements.
Refrigerant tubing and indoor coil are now ready for leak testing.
This check should include all field and factory joints.
3
Refer to Fig. 3 and install filter drier as follows:
1. Braze 5--in. liquid tube to the indoor coil.
2. Wrap filter drier with damp cloth.
Make Electrical Connections
Be sure field wiring complies with local and national fire, safety,
and electrical codes, and voltage to system is within limits shown
on unit rating plate. Contact local power company for correction of
improper voltage. See unit rating plate for recommended circuit
protection device.
3. Braze filter drier to above 5--in. (127 mm) liquid tube.
Flow arrow must point towards indoor coil.
4. Connect and braze liquid refrigerant tube to the filter drier.
NOTE: Operation of unit on improper line voltage constitutes
abuse and could affect unit reliability. See unit rating plate. Do not
install unit in system where voltage may fluctuate above or below
permissible limits.
NOTE: Use copper wire only between disconnect switch and unit.
NOTE: Install branch circuit disconnect of adequate size per NEC
to handle unit starting current. Locate disconnect within sight from
and readily accessible from unit, per Section 440--14 of NEC.
A05178
Route Ground and Power Wires
Fig. 3 -- Liquid Line Filter Drier
Remove access panel to gain access to unit wiring. Extend wires
from disconnect through power wiring hole provided and into unit
control box.
Evacuate Refrigerant Tubing and Indoor Coil
!
CAUTION
!
WARNING
UNIT DAMAGE HAZARD
ELECTRICAL SHOCK HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Failure to follow this warning could result in personal injury or
death.
Never use the system compressor as a vacuum pump.
The unit cabinet must have an uninterrupted or unbroken
ground to minimize personal injury if an electrical fault should
occur. The ground may consist of electrical wire or metal
conduit when installed in accordance with existing electrical
codes.
Refrigerant tubes and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. The alternate
triple evacuation method may be used (see triple evacuation
procedure in service manual). Always break a vacuum with dry
nitrogen.
Connect Ground and Power Wires
Connect ground wire to ground connection in control box for
safety. Connect power wiring to contactor as shown in Fig. 5.
Deep Vacuum Method
The deep vacuum method requires a vacuum pump capable of
pulling a vacuum of 500 microns and a vacuum gage capable of
accurately measuring this vacuum depth. The deep vacuum method
is the most positive way of assuring a system is free of air and
liquid water. A tight dry system will hold a vacuum of 1000
microns after approximately 7 minutes. See Fig. 4.
DISCONNECT
PER N. E. C. AND/OR
LOCAL CODES
CONTACTOR
FIELD POWER
WIRING
5000
4500
4000
FIELD GROUND
LEAK IN
3500
WIRING
SYSTEM
GROUND
LUG
3000
2500
2000
1500
1000
A91056
Fig. 5 -- Line Connections
VACUUM TIGHT
TOO WET
Connect Control Wiring
TIGHT
500
DRY SYSTEM
This unit is capable of communication with an Evolution Control,
or will operate using standard 24v 2--stage thermostat. Route 24--v
control wires through control wiring grommet and connect leads to
control board. When an Evolution User Interface is available,
connect A, B, C and D connections only. If a 2--stage thermostat is
used, connect to the R, C, Y1, and Y2 connections. Refer to the
wiring label to further clarification.
0
1
2
3
4
5
6
7
MINUTES
A95424
Fig. 4 -- Deep Vacuum Graph
Final Tubing Check
IMPORTANT: Check to be certain factory tubing on both indoor
and outdoor unit has not shifted during shipment. Ensure tubes are
not rubbing against each other or any sheet metal or wires. Pay
close attention to feeder tubes, making sure wire ties on feeder
tubes are secure and tight.
Use No. 18 AWG color--coded, insulated (35_C minimum) wire. If
thermostat is located more than 100 ft. (30.48 m) from unit, as
measured along the control voltage wires, use No. 16 AWG
color--coded wire to avoid excessive voltage drop.
All wiring must be NEC Class 1 and must be separated from
incoming power leads.
Use furnace transformer, fan coil transformer, or accessory
transformer for control power, 24v/40va minimum.
NOTE: Use of available 24v accessories may exceed the
minimum 40va power requirement. Determine total transformer
loading and increase the transformer capacity or split the load with
an accessory transformer as required.
4
quired airflow shown in the air conditioning Product Data
for LOW speed. If a higher or lower continuous fan speed is
desired, the continuous fan speed can be changed using the
fan switch on the thermostat. Refer to the furnace Installa-
tion Instructions for details of how to use this feature.
Final Wiring Check
IMPORTANT: Check factory wiring and field wire connections
to ensure terminations are secured properly. Check wire routing to
ensure wires are not in contact with tubing, sheet metal, etc.
Compressor Crankcase Heater
Airflow Selection for FV4C Fan Coils (non--com-
municating)
The FV4 provides high-- and low--stage blower operation to match
the capacities of the compressor at high-- and low--stage.
When equipped with a crankcase heater, furnish power to heater a
minimum of 24 hr before starting unit. To furnish power to heater
only, set thermostat to OFF and close electrical disconnect to
outdoor unit.
To select recommended airflow, refer to the FV4C Installation
Instructions. The FV4C utilizes an Easy Select control board that
allows the installing technician to select proper airflows. This fan
coil has an adjustable blower--off delay factory set at 90 sec. for
high-- and low--stage blower operation.
When using a communicating control with the fan coil or the
furnace, dip--switch adjustments are not necessary. The outdoor
unit configuration and the indoor airflows are determined by
communicating control setup.
A crankcase heater is required if refrigerant tubing is longer than
80 ft. (24.38 m). Refer to the Application Guideline and Service
Manual Longline Section--Residential Split--System Air
Conditioners and Heat Pumps.
Airflow Setup for Evolution Control Furnace or
FE Fan Coil (communicating)
When using an Evolution User Interface, airflow is automatically
selected based on equipment size. See User Interface Installation
Instructions for available adjustments.
Start--Up
Airflow Selections (ECM Furnaces -- non commu-
nicating)
The ECM Furnaces provide blower operation to match the
capacities of the compressor during high and low stage cooling
operation. Tap selections on the furnace control board enable the
installing technician to select the proper airflows for each stage of
cooling. Below is a brief summary of the furnace airflow
configurations
!
CAUTION
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this caution may result in personal injury,
equipment damage or improper operation.
S Do not overcharge system with refrigerant.
S Do not operate unit in a vacuum or at negative pressure.
S Compressor dome temperatures may be hot.
1. The Y2 call for high stage cooling energizes the “Cool” tap
on the control board. The grey wire from cool tap is connec-
ted to tap 5 on the motor. Refer to the furnace Product Data
to find the corresponding airflow. If the airflow setting for
high cooling needs to be switched from tap 5 to a different
tap, jumper a connection from the cool tap to the desired tap
so that the Y2 signal is communicated via the cool tap to the
desired speed tap.
!
CAUTION
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal injury.
Wear safety glasses, protective clothing, and gloves when
handling refrigerant and observe the following:
S Front seating service valves are equipped with Schrader
2. The Y1 call for low stage cooling energizes the “Fan” tap
on the control board. The red wire from the fan tap is con-
nected to tap 1 on the motor. Refer to the furnace Product
Data to find the corresponding airflow. If the airflow setting
for low cooling needs to be switched from tap 1 to a differ-
ent tap, jumper a connection from the Fan tap to the desired
tap so that the Y1 signal is communicated via the Fan tap to
the desired speed tap. The Y1 setting will also govern the
continuous fan airflow for the furnace.
valves.
SYSTEM FUNCTIONS AND SEQUENCE
OF OPERATION
The 180B
/
187B models utilize either an Evolution
Communicating User Interface or a 2-stage cooling indoor
thermostat. With a call for first stage cooling, the outdoor fan and
low-stage compressor are energized. If low-stage cannot satisfy
cooling demand, high-stage is energized by the second stage of
indoor thermostat. After second stage is satisfied, the unit returns to
low-stage operation until first stage is satisfied or until second stage
is required again.
Refer to the literature for the furnace for further details.
Airflow Selection for Variable Speed Furnaces
(non--communicating)
The variable speed furnaces provide blower operation to match the
capacities of the compressor during high and low stage cooling
operation. The furnace control board allows the installing
technician to select the proper airflows for each stage of cooling.
Below is a summary of required adjustments. See furnace
installation instructions for more details:
When both first stage and second stage cooling are satisfied, the
compressor will shut off. When a 2-stage unit is operating at
low-stage, system vapor (suction) pressure will be higher than a
standard single-stage system or high-stage operation.
When the outdoor ambient is more than 100_F (37.8_C), the
outdoor fan will continue to run for one minute after compressor
shuts off. this reduces pressure differential for easier starting in the
next cycle.
1. Turn SW1----5 ON for 400 CFM/ton airflow or OFF for 350
CFM/ton airflow. Factory default is OFF.
2. The A/C DIP switch setting determines airflow during high
stage cooling operation. Select the A/C DIP switch setting
corresponding to the available airflow shown in the furnace
Installation Instructions that most closely matches the re-
quired airflow shown in the air conditioning Product Data
for HIGH speed.
3. The CF DIP switch setting determines airflow during low
stage cooling operation. Select the CF DIP switch setting
corresponding to the available airflow shown in the furnace
installation instructions that most closely matches the re-
5
Communication and Status Function Lights
Outdoor Fan Motor Operation
The outdoor unit control energizes the outdoor fan any time the
compressor is operating except for low--ambient cooling operation.
For Evolution Control Only, Green communications
(COMM)Light
The outdoor fan remains energized if a pressure switch or
compressor overload should open. Outdoor fan motor will
continue to operate for one minute after the compressor shuts off
when the outdoor ambient is greater than or equal to 100_F
(37.78_C) to allow for easier starting during next cooling cycle.
On 187B models -- The outdoor fan motor is a PSC type. A fan
relay on the control board turns the fan off and on by opening and
closing a high voltage circuit to the motor. It does not change
speeds between low and high stage operation.
Green LED (COMM Light)
A green LED (COMM light) on the outdoor board (see Fig. 6)
indicates successful communication with the other system
products. The green LED will remain OFF until communications is
established. Once a valid command is received, the green LED will
turn ON continuously. If no communication is received within 2
minutes, the LED will be turned OFF until the next valid
communication.
Amber Status Light
On 180B models -- The outdoor fan is an ECM type. The motor
control is continuously powered with high voltage. The motor
speed is determined by electrical pulses provided by the PWM
outputs on the control board. The ECM motor RPM adjusts to
outdoor conditions as described in Table 3. The PWM output can
be measured between the PWM1 and PWM2 terminals on the
circuit board with a volt meter set to DC volts.
An amber colored STATUS light is used to display the operation
mode and fault codes as specified in the troubleshooting section.
See Table 6 for codes and definitions.
NOTE: Only one code will be displayed on the outdoor unit
control board (the most recent, with the highest priority).
Utility Interface with Evolution Control
Table 3 – Outdoor Fan Motor PWM
Outdoor Temp (DC volts, Tolerance +/-- 2%)
LOW--- &
The utility curtailment relay should be wired between R and Y2
connections on the control board for Evolution Communicating
Systems only (see Fig. 6). This input allows a power utility device
to interrupt compressor operation during peak load periods. When
the utility sends a signal to shut the system down, the User
Interface will display, “Curtailment Active”.
L O W --- S T A G E
H I G H --- S T A G E
MODEL
HIGH---STAGE
(OAT≤104_F/40_C)
(OAT≤104_F/40_C)
(OAT>104_F/40_C)
180B036
9.06
10.23
11.90
NOTE:
For 180A models in low---ambient cooling, the PWM output for both high---
and low---stage equals the value for low---stage operation below 55_F
(12.8_C).
Compressor Operation
The basic scroll design has been modified with the addition of an
internal unloading mechanism that opens a by--pass port in the first
compression pocket, effectively reducing the displacement of the
scroll.
In low ambient cooling (below 55_F/12.78_C) on 187B and 180B
models, the control board cycles the fan off and on.
Time Delays
The unit time delays include:
The opening and closing of the by--pass port is controlled by an
internal electrically operated solenoid. The modulated scroll uses a
single step of unloading to go from full capacity to approximately
67% capacity. A single speed, high efficiency motor continues to
run while the scroll modulates between the two capacity steps.
S Five minute time delay to start cooling or heating operation
when there is a call from the thermostat or user interface. To
bypass this feature, momentarily short and release Forced
Defrost pins.
S Five minute compressor re--cycle delay on return from a
brown--out condition.
S Two minute time delay to return to standby operation from last
valid communication (with Evolution only).
S One minute time delay of outdoor fan at termination of cooling
mode when outdoor ambient is greater than or equal to 100_F
(37.78_C).
S There is no delay between staging from low to high and from
high to low capacity. The compressor will change from low to
high and from high to low capacity “on the fly” to meet the
demand.
Modulation is achieved by venting a portion of the gas in the first
suction pocket back to the low side of the compressor, thereby
reducing the effective displacement of the compressor. Full
capacity is achieved by blocking these vents, thus increasing the
displacement to 100%.
A DC solenoid in the compressor controlled by a rectified 24 volt
AC signal in the external solenoid plug moves the slider ring that
covers and uncovers these vents. The vent covers are arranged in
such a manner that the compressor operates at approximately 67%
capacity when the solenoid is not energized and 100% capacity
when the solenoid is energized. The loading and unloading of the
two step scroll is done “on the fly” without shutting off the motor
between steps.
NOTE: 67% compressor capacity translates to approximately
75% cooling capacity at the indoor coil. The compressor will
always start unloaded and stay unloaded for five seconds even
when the thermostat is calling for high--stage capacity.
Crankcase Heater Operation
The crankcase heater is energized during off cycle below 65_F
(18.33_C).
6
MODEL
PLUG
MODEL
PLUG
UTILITY RELAY
*
UTILITY SIGNAL
OPEN RELAY
LLS
Liquid Line Solenoid
*
SUPPLIED BY UTILITY PROVIDER
A06526
Fig. 6 -- 2--Stage Control Board
Evolution Controlled Low Ambient Cooling
Check Charge
This unit is capable of low ambient cooling down to 0_F
(--17.78_C) without a kit -- ONLY when using Evolution control.
A low ambient kit is not required, and the outdoor fan motor does
not need to be replaced for Evolution controlled low ambient
operation.
The Evolution Control provides an automatic evaporator coil
freeze protection algorithm that eliminates the need for an
evaporator freeze thermostat. Low ambient cooling must be
enabled in the User Interface set up. Fan may not begin to cycle
until about 40_F (4.4_C) OAT. Fan will cycle based on coil and
outdoor air temperature.
Models 180B / 187B should be charged in high stage compressor
operation. Factory charge amount and desired subcooling are
shown on unit rating plate. Charging method is shown on
information plate inside unit. To properly check or adjust charge,
conditions must be favorable for subcooling charging. Favorable
conditions exist when the outdoor temperature is between 70_F
and 100_F (21.11_C and 37.78_C), and the indoor temperature is
between 70_F and 80_F (21.11_C and 26.67_C). Follow the
procedure below:
Unit is factory charged for 15ft (4.57 m) of lineset. Adjust charge
by adding or removing 0.6 oz/ft of 3/8 liquid line above or below
15ft (4.57 m) respectively.
Evolution controlled low ambient mode operates as follows:
For standard refrigerant line lengths (80 ft/24.38 m or less), allow
system to operate in cooling mode at least 15 minutes. If conditions
are favorable, check system charge by subcooling method. If any
adjustment is necessary, adjust charge slowly and allow system to
operate for 15 minutes to stabilize before declaring a properly
charged system.
—
Fan is OFF when outdoor coil temp is less than outdoor
air temperature (+3_F / 1.67_C) or outdoor fan has been
ON for 30 minutes. (Fan is turned off to allow refrigerant
system to stabilize.)
—
Fan is ON when outdoor coil temp is more than outdoor
air temperature (+ 25_F / 13.89_C) or outdoor coil temp
is more than 80_F (26.67_C) or if outdoor fan has been
OFF for 30 minutes. (Fan is turned on to allow
refrigerant system to stabilize.)
Low pressure switch is ignored for first 3 minutes during
low ambient start up. After 3 minutes, if LPS trips, then
outdoor fan motor is turned off for 10 minutes with the
compressor running. If LPS closes within 10 minutes,
then cooling continues with the outdoor fan cycling per
the coil temperature routine listed above for the
remainder of the cooling cycle. If the LPS does not close
within 10 minutes, then the normal LPS trip response
(shut down cooling operation and generate LPS trip
error) will occur.
If the indoor temperature is above 80_F (26.67_C), and the
outdoor temperature is in the favorable range, adjust system charge
by weight based on line length and allow the indoor temperature to
drop to 80_F (26.67_C) before attempting to check system charge
by subcooling method as described above.
—
If the indoor temperature is below 70_F (21.11_C), or the outdoor
temperature is not in the favorable range, adjust charge for line set
length above or below 15ft (4.57 m) only. Charge level should then
be appropriate for the system to achieve rated capacity. The charge
level could then be checked at another time when the both indoor
and outdoor temperatures are in a more favorable range.
NOTE: If line length is beyond 80 ft (24.38 m) or greater than 20
ft (6.10 m) vertical separation, See Long Line Guideline for
special charging requirements.
—
The PWM output for both high and low--stage equals the
value for low--stage operation, below 55_F (12.8_C).
7
Final Checks
IMPORTANT: Before leaving job, be sure to do the following:
CARE AND MAINTENANCE
For continuing high performance and to minimize possible
equipment failure, periodic maintenance must be performed on this
equipment.
1. Ensure that all wiring is routed away from tubing and sheet
metal edges to prevent rub--through or wire pinching.
Frequency of maintenance may vary depending upon geographic
areas, such as coastal applications. See Owner’s Manual for
information.
2. Ensure that all wiring and tubing is secure in unit before
adding panels and covers. Securely fasten all panels and
covers.
3. Tighten service valve stem caps to 1/12--turn past finger
tight.
4. Leave Owner’s Manual with owner. Explain system opera-
tion and periodic maintenance requirements outlined in
manual.
5. Fill out Dealer Installation Checklist and place in customer
file.
8
Control Fault
TROUBLESHOOTING
If the outdoor unit control board has failed, the control will flash
the appropriate fault code. (See Table 6) The control board should
be replaced.
If the compressor fails to operate with a cooling call, Table 4 can be
used to verify if there is any damage to the compressor windings
causing system malfunction.
Brown Out Protection
Table 4 – Winding Resistance
Winding resistance at 70_F + / --- 2 0 _F
If the line voltage is less than 187v for at least 4 seconds, the
appropriate compressor contactor and fan relay are de--energized.
Compressor and fan operation are not allowed until voltage is a
minimum of 190v. The control will flash the appropriate fault code
(see Table 6)
(21.11_C +/--- 11.11_C)
Winding
187B036 /
180B036
1.98
187B024
187B048
187B060
Star t (S --- C)
Ru n (R --- C)
2.74
0.8
1.55
0.48
0.6
0.49
0.75
230 V Brown Out Protection Defeated:
Systems Communication Failure
The brownout feature can be defeated if needed for severe noisy
power conditions. This defeat should always be a last resort to
solving the problem. Defeat is available on the User Interface
setup screen (available with SYSTXBBUID01--C UI) or can be
initiated through the forced defrost pins for non--communicating
systems as follows:
If communication with the Evolution Control is lost with the user
interface, the control will flash the appropriate fault code. (See
Table 6) Check the wiring to the User Interface, indoor and
outdoor units.
Model Plug
Each control board contains a model plug. The correct model plug
must be installed for or the system to operate properly (see Table
5).
The brownout toggle is accomplished by shorting the defrost pins
from power up with the OAT and OCT sensor connector removed.
After 3 seconds, the status of the force defrost short and the
OAT/OCT as open will be checked. If correct, then the brownout
will be toggled.
Table 5 – Model Plug
Pin Resistance
Model
Number
Model Plug
Number
(k - Ohms)
S Status code 6 shows the brownout is disabled.
Pin 1 - 4
Pin 2 - 3
S Status code 5 shows the brownout is active.
187B024
187B036
180B036
187B048
187B060
Hk70EZ040
Hk70EZ042
Hk70EZ011
Hk70EZ044
Hk70EZ046
18K
18K
5.1K
18K
18K
75K
120K
150K
180K
270K
After the brownout defeat is set, power down and reinstall the
OAT/OCT sensor and remove the short from the forced defrost
pins. As long as the short on the forced defrost remains, the OAT
and OCT faults will not be cleared. The code will continue to be
flashed.
The model plug is used to identify the type and size of unit to the
control.
The control is shipped with the brownout active. The change in
status is remembered until toggled to a new status. A power
down/power up sequence will not reset the status. It may be
necessary to do the toggle twice to cycle to the desired state of the
defeat.
On new units, the model and serial numbers are input into the
board’s memory at the factory. If a model plug is lost or missing at
initial installation, the unit will operate according to the
information input at the factory and the appropriate error code will
flash temporarily.
An RCD replacement board contains no model and serial
information. If the factory control board fails, the model plug must
be transferred from the original board to the replacement board for
the unit to operate.
230V Line (Power Disconnect) Detection
If there is no 230v at the compressor contactor(s) when the indoor
unit is powered and cooling demand exists, the appropriate error
code is displayed (see Table 6). Verify that the disconnect is closed
and 230v wiring is connected to the unit.
NOTE: The model plug takes priority over factory model
information input at the factory. If the model plug is removed after
initial power up, the unit will operate according to the last valid
model plug installed, and flash the appropriate fault code
temporarily.
Compressor Voltage Sensing
The control board input terminals labeled VS and L2 (see Fig. 6)
are used to detect compressor voltage status, and alert the user of
potential problems. The control continuously monitors the high
voltage on the run capacitor of the compressor motor. Voltage
should be present any time the compressor contactor is energized,
and voltage should not be present when the contactor is
de--energized.
Pressure Switch Protection
The outdoor unit is equipped with high and low pressure switches.
If the control senses the opening of a high or low pressure switch,
it will respond as follows:
Contactor Shorted Detection
If there is compressor voltage sensed when there is no demand for
compressor operation, the contactor may be stuck closed or there is
a wiring error. The control will flash the appropriate fault code.
1. De--energize the appropriate compressor contactor,
2. Keep the outdoor fan operating for 15 minutes,
3. Display the appropriate fault code (see Table 6).
4. After a 15 minute delay, if there is still a call for cooling and
the LPS or HPS is reset, the appropriate compressor contac-
tor is energized.
Compressor Thermal Cutout
If the control senses the compressor voltage after start--up, and is
then absent for 10 consecutive seconds while cooling demand
exists, the thermal protector is open. The control de--energizes the
compressor contactor for 15 minutes, but continues to operate the
outdoor fan.
5. If LPS or HPS has not closed after a 15 minute delay, the
outdoor fan is turned off. If the open switch closes anytime
after the 15 minute delay, then resume operation with a call
for cooling.
The control Status LED will flash the appropriate code shown in
Table 6. After 15 minutes, with a call for low or high stage cooling,
the compressor contactor is energized. If the thermal protector has
not reset, the outdoor fan is turned off. If the call for cooling
continues, the control will energize the compressor contactor every
15 minutes. If the thermal protector closes, (at the next 15 minute
interval check), the unit will resume operation. If the thermal
6. If LPS or HPS trips 3 consecutive cycles, the unit operation
is locked out for 4 hours.
7. In the event of a high pressure switch trip or high pressure
lockout, check the refrigerant charge outdoor fan operation
and outdoor coil for airflow restrictions.
8. In the event of a low pressure switch trip or low pressure
lockout, check the refrigerant charge and indoor airflow.
9
cutout trips for three consecutive cycles, then unit operation is
locked out for 4 hours and the appropriate fault code is displayed.
2--Stage Compressor
The 2--stage compressor contains motor windings that provide
2--pole (3500 RPM) operation. Refer to Table 4 for correct
winding resistance.
No 230V at Compressor
If the compressor voltage is not sensed when the compressor
should be starting, the appropriate contactor may be stuck open or
there is a wiring error. The control will flash the appropriate fault
code. Check the contactor and control box wiring.
Compressor Internal Relief
The compressor is protected by an internal pressure relief (IPR)
which relieves discharge gas into compressor shell when
differential between suction and discharge pressures exceeds 550 --
625 psi The compressor is also protected by an internal overload
attached to motor windings.
Troubleshooting units for proper switching
between low & high stages
Check the suction pressures at the service valves. Suction pressure
should be reduced by 3--10% when switching from low to high
capacity.
NOTE: The liquid pressures are very similar between low and
high stage operation so liquid pressure should not be used for
troubleshooting.
Compressor Control Contactor
The contactor has a 24 volt coil. The electronic control board
controls the operation of the appropriate contactor.
TEMPERATURE THERMISTORS
Thermistors are electronic devices which sense temperature. As the
temperature increases, the resistance decreases. Thermistors are
used to sense outdoor ambient (OAT) and coil temperature (OCT).
Refer to Fig. 7 for resistance values versus temperature. If the
outdoor ambient or coil thermistor should fail, the control will
flash the appropriate fault code (see Table 6.)
Compressor current should increase 20--45% when switching from
low to high stage. The compressor solenoid, when energized in
high stage, should measure 24vac. When the compressor is
operating in low stage the 24v DC compressor solenoid coil is
de--energized. When the compressor is operating in high stage, the
24v DC solenoid coil is energized. The solenoid plug harness that
is connected to the compressor has an internal rectifier that
converts the 24v DC signal to 24v AC.
IMPORTANT: Outdoor air thermistor and coil thermistor are
factory mounted in the final locations. Check to insure thermistors
are mounted properly per Fig. 8 and Fig. 9.
NOTE: DO NOT INSTALL A PLUG WITHOUT AN
INTERNAL RECTIFIER.
Thermistor Sensor Comparison
The control continuously monitors and compares the outdoor air
temperature sensor and outdoor coil temperature sensor to ensure
proper operating conditions. The comparison is:
Unloader Test Procedure
The unloader is the compressor internal mechanism, controlled by
the DC solenoid, that modulates between high and low stage. If it
is suspected that the unloader is not working, the following
methods may be used to verify operation.
—
If the outdoor air sensor indicates 10_F (5.56_C) warmer
than the coil sensor (or) the outdoor air sensor indicates
20_F (11.11_C) cooler than the coil sensor, the sensors
are out of range.
1. Operate the system and measure compressor amperage.
Cycle the unloader on and off at 30 second plus intervals at
the UI (from low to high stage and back to low stage). Wait
5 seconds after staging to high before taking a reading. The
compressor amperage should go up or down at least 20 per-
cent.
—
—
If the sensors are out of range, the control will flash the
appropriate fault code as shown in Table 6.
The thermistor comparison is not performed during low
ambient cooling or defrost operation.
2. If step one does not give the expected results, remove the
solenoid plug from the compressor and, with the unit run-
ning and the UI (or Thermostat) calling for high stage, test
the voltage output at the plug with a DC voltmeter. The
reading should be 24 volts DC.
Failed Thermistor Default Operation
Factory defaults have been provided in the event of failure of
outdoor air thermistor and/or coil thermistor.
If the OAT sensor should fail, low ambient cooling will not be
allowed and the one minute outdoor fan--off delay will not occur.
3. If the correct DC voltage is at the control circuit molded
plug, measure the compressor unloader coil resistance. The
resistance should be 32 to 60 ohms depending on com-
pressor temperature. If the coil resistance is infinite, much
lower than 32 ohms, or is grounded, the compressor must
be replaced.
If the OCT sensor should fail, low ambient cooling will not be
allowed.
OAT Thermistor must be locked in place with spherical nib end
facing towards the front of the control box
THERMISTOR CURVE
MAJOR COMPONENTS
2--Stage Control
90
80
70
60
50
40
30
20
The 2--stage control board controls the following functions:
—
—
—
—
—
—
Compressor high and low stage operation
Outdoor fan motor operation
Low ambient cooling
Compressor external protection
Pressure switch monitoring
Time delays
10
0
Field Connections
0
20
40
60
80
100
120
(-17.77) (-6.67)
(4.44)
(15.56) (26.67) (37.78) (48.89)
On models with non--communicating (non--Evolution) system, the
2--stage control receives 24vac low--voltage control system inputs
through the R, C, Y1, and Y2 connections located at the bottom of
the control board (see Fig. 6). The OD units can be controlled
using a standard 2--stage thermostat or Evolution User Interface.
TEMPERATURE °F (°C)
A08054
Fig. 7 -- Resistance Values Versus Temperature
10
OAT Thermistor must be
locked in place with spherical
nib end facing towards the
front of the control box
OCT Thermistor must be
secured tight on the liquid tube.
Fig. 9 -- Outdoor Coil Thermistor (OCT) Attachment
Fig. 8 -- Outdoor Air Thermistor (OAT) Attachment
Table 6 – TROUBLESHOOTING
AMBER
LED
FLASH
CODE
OPERATION
FAULT
POSSIBLE CAUSE AND ACTION
On sol-
id, no
flash
Standby – no call for unit op-
eration
None
Normal operation
L ow --- stage Cool /Heat Oper a-
None
None
1, pause
2, pause
16
Normal operation
Normal operation
tion
High-stage Cool/Heat Opera-
tion
System Communications
Failure
Communication with user interface lost. Check wiring to User Interface, indoor
and outdoor units
Control does not detect a model plug or detects an invalid model plug. Unit
will not operate without correct model plug.
Invalid Model Plug
25
High---pressure switch trip. Check refrigerant charge, outdoor fan operation
and coils for airflow restrictions.
High Pressure Switch Open
31*
Low Pressure Switch Open
Control Fault
32*
45
Low pressure switch trip. Check refrigerant charge and indoor air flow
Outdoor unit control board has failed. Control board needs to be replaced.
Line voltage < 187v for at least 4 seconds. Compressor and fan operation not
allowed until voltage>190v. Verify line voltage.
Brown Out (230 v)
46
There is no 230v at the contactor when indoor unit is powered and cooling/
heating demand exists. Verify the disconnect is closed and 230v wiring is
connected to the unit.
No 230v at Unit
47
Outdoor Air Temp Sensor
Fault
Outdoor Coil Sensor Fault
Outdoor air sensor not reading or out of range. Ohm out sensor and check
53
55
56
wiring.
Coil sensor not reading or out of range. Ohm out sensor and check wiring.
Improper relationship between coil sensor and outdoor air sensor. Ohm out
sensors and check wiring.
Thermistors out of range
Compressor operation detected then disappears while low---stage demand
exists. Possible causes are internal compressor overload trip or start relay and
capacitor held in circuit too long(if installed)
Compressor operation detected then disappears while high---stage demand
exists. Possible causes are internal compressor overload trip or start relay and
capacitor held in circuit too long (if installed)
Low stage Thermal Cutout
High stage Thermal Cutout
71*
72*
Compressor voltage sensed when no demand for compressor operation
exists. Contactor may be stuck closed or there is a wiring error.
Compressor voltage not sensed when compressor should be starting. Contac-
tor may be stuck open or there is a wiring error.
Thermal cutout occurs in three consecutive low/ high---stage cycles.
low---stage locked out for 4 hours or until 24v power recycled.
Thermal cutout occurs in three consecutive high/low---stage cycles.
high---stage locked out for 4 hours or until 24v power recycled.
Low pressure switch trip has occurred during 3 consecutive cycles. Unit oper-
ation locked out for 4 hours or until 24v power recycled.
High pressure switch trip has occurred during 3 consecutive cycles. Unit oper-
ation locked out for 4 hours or until 24v power recycled.
Contactor Shorted
73
74
81
82
83
84
No 230V at Compressor
Low-stage Thermal Lockout
High-stage Thermal Lock-
out
Low Pressure Lockout
High Pressure Lockout
* Sequence: Compressor contactor is de-energized and outdoor fan is energized for up to 15 minutes. If demand still exists, control will energize compressor.
11
Two-Stage
Air Conditioner
Variable Speed
Fan Coil
Variable Speed
Furnace
2-Stage
Air Conditioner
Thermidistat
Thermidistat
O
Y1
Y1
W1
Heat Stage 2
O/B W2
W/W1
Y1 / W2
Y/Y2
G
W2
W1
RVS/Heat Stage 2
O/W2/B
W/W1
Y1
Heat Stage 1
Cool Stage 1
Heat Stage 1
Compressor Low
Compressor High
Fan
REMOVE J2
JUMPER FOR
HEAT STAGING
Y1
W2
Y/Y2
G
Cool Stage 2
Y/Y2
G
Y/Y2
Y2
Y/Y2
G
Fan
R
24VAC Hot Heating
24VAC Hot Cooling
Dry Contact 1
Dry Contact 2
24VAC Common
Humidify
Rh
R
R
C
24VAC Hot Heating
24VAC Hot Cooling
Dry Contact 1
Rh
R
REMOVE J1 FOR
DEHUMIDIFY
MODES
Rc
Rc
DH
C
D1
D1
C
D2
DHUM
COM
Dry Contact 2
D2
C
24VAC Common
Humidify
C
*
HUM
OAT
HUM
*
Outdoor Air Temp
Remote Room Sensor
OAT/RRS Com
Outdoor Air Temp
Remote Room Sensor
OAT
RRS
RRS
Outdoor Sensor *
Outdoor Sensor
SRTN
Remote Room
Sensor *
OAT/RRS Return
SRTN
SRTN
Remote Room
Sensor
* See Humidifier Instructions for proper wiring
* See Humidifier Instructions for proper wiring.
A09566
A09565
T h er midistat Model s T 6 --- PRH01 --- A & T 6 --- NRH01 --- A
w/ VS Fan Coil & 2---Stage Air Conditioner
T h er midistat Model T 6 --- PRH01 --- A & T 6 --- NRH01 --- A
w/ VS Furnace & 2---Stage Air Conditioner
Fig. 10 -- Thermidistat Wiring with 2--Stage Puron refrigerant Air Conditioner
R
R
*
*
* See Humidifier Instructions for proper wiring.
* See Humidifier Instructions for proper wiring.
A09568
A09567
2 --- Stage T h er mostat with Sin gl e --- Stage Fu r n ace an d
2---Stage Air Conditioner
Single Stage Furnace with 2---Stage Air Conditioner
Fig. 11 -- VS Furnace or Fan Coil Wiring with Communicating 2--Stage AC
Communicating AC//HP
User Interface
Fan Coil
D
C
B
A
D
C
B
A
D
C
B
A
* See Humidifier Instructions for proper wiring.
A09569
Fig. 12 -- Evolution Furnace or Fan Coil with Communicating 2--Stage AC Wiring Diagram
(See Thermostat Installation Instruction for specific unit combinations)
12
PURONR (R--410A) REFRIGERANT QUICK REFERENCE GUIDE
S Puron refrigerant operates at 50--70 percent higher pressures than R--22. Be sure that servicing equipment and replacement
components are designed to operate with Puron refrigerant
S Puron refrigerant cylinders are rose colored.
S Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
S Puron refrigerant systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose
when charging into suction line with compressor operating
S Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low--side retard.
S Use hoses with 700 psig service pressure rating.
S Leak detectors should be designed to detect HFC refrigerant.
S Puron refrigerant, as with other HFCs, is only compatible with POE oils.
S Vacuum pumps will not remove moisture from oil.
S Do not use liquid--line filter driers with rated working pressures less than 600 psig.
S Do not leave Puron suction line filter driers in line longer than 72 hours.
S Do not install a suction--line filter drier in liquid line.
S POE oils absorb moisture rapidly. Do not expose oil to atmosphere.
S POE oils may cause damage to certain plastics and roofing materials.
S Wrap all filter driers and service valves with wet cloth when brazing.
S A factory approved liquid--line filter drier is required on every unit.
S Do NOT use an R--22 TXV.
S If indoor unit is equipped with an R--22 TXV or piston metering device, it must be changed to a hard shutoff Puron TXV.
S Never open system to atmosphere while it is under a vacuum.
S When system must be opened for service, recover refrigerant, evacuate then break vacuum with dry nitrogen and replace filter driers.
Evacuate to 500 microns prior to recharging.
S Do not vent Puron refrigerant into the atmosphere.
S Do not use capillary tube coils.
S Observe all warnings, cautions, and bold text.
S All indoor coils must be installed with a hard shutoff Puron TXV metering device.
13
E2010 Bryant Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231
Printed in U.S.A.
Edition Date: 02/10
Catalog No. II180---187B---01
Replaces: New
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
14
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