{"id":21278,"date":"2022-08-25T09:31:36","date_gmt":"2022-08-25T16:31:36","guid":{"rendered":"http:\/\/www.hvacredu.net\/staging\/?p=21278"},"modified":"2022-08-25T09:32:06","modified_gmt":"2022-08-25T16:32:06","slug":"mini-splits-for-new-hvac-techs-by-ryan-findley","status":"publish","type":"post","link":"https:\/\/www.hvacredu.net\/staging\/mini-splits-for-new-hvac-techs-by-ryan-findley\/","title":{"rendered":"Mini Splits For New HVAC Techs – by Ryan Findley"},"content":{"rendered":"\t\t
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\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"Ryan\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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This article will be geared for HVAC techs who are new to mini splits.\u00a0 As the mini split market continues to grow, technicians face more and more challenges with these systems.\u00a0 The largest challenges would be the lack of training, and not having the proper tools to be effective working on them.\u00a0 Please go to as much manufacturer training as your employer will allow.\u00a0 I will attempt to give you some of the highlights of how they work, how to troubleshoot, and what tools you will need to be effective at troubleshooting them. <\/span><\/p>

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How they are different:<\/span><\/p><\/span><\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Mini splits, like their bigger cousins the VRF machines, have a lot of mystique that surrounds them that is unjustly warranted.\u00a0 They still operate under the same rules of thermodynamics that standard unitary equipment does, they just do it in a little different way.\u00a0 Let\u2019s dive into what\u2019s different about them.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Inverter driven compressors<\/span><\/span><\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Right off the start, these systems use an inverter driven compressor (some have an ac compressor, others have a dc compressor, refer to manufacturers literature or data plate) to control capacity.\u00a0 A circuit board either rectifies incoming power to dc then inverts it back to ac to drive the compressor or simply controls the dc output to produce a variable speed effect.\u00a0 Compressor speeds are a function of meeting either the target evaporator temp (cooling mode) or the target condensing temp (heating mode).\u00a0 TE (target evap) and TC (target condenser) calculation comes from how far off setpoint the return air temp\/room controller temp\/remote controller temp is.\u00a0 The farther off setpoint that it is, the faster the compressor will run (the lower the TE or the higher the TC).\u00a0 Run speed is published typically in rps (revolutions per second).\u00a0 The typical range on most units is 25-120 rps.\u00a0\u00a0<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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EEVs<\/span><\/span><\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Electronic expansion valves are electronically controlled devices that meter the flow of refrigerant through the system.\u00a0 1 to 1 units will have 1 expansion valve while multi splits will have 1 per port that it has.\u00a0 If it\u2019s a 4 port unit, there will be 4 EEVs in the machine.\u00a0 Each EEV controls refrigerant flow to each indoor coil attached.\u00a0 EEVs are either controlling the superheat (ac mode) or the subcooling (heating mode).\u00a0 Superheat\/subcooling targets (the number that it\u2019s aiming to get to) are anywhere from 8-15 and typically vary depending on how far off setpoint you are.\u00a0 This is important information to remember as it will help you evaluate the charge without weighing it out just yet.\u00a0 We will touch on EEVs later.\u00a0<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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4 Way Valve<\/span><\/span><\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Commonly called the reversing valve in unitary equipment, is a device used to divert refrigerant either to the indoor coil for heating mode or outdoor coil for cooling mode.\u00a0 Most manufacturers’ valves default to cooling and energize in heating mode.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Thermistors<\/span><\/span><\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Thermistors are devices that change resistance based upon temperature.\u00a0 Common thermistor types are: discharge pipe temp, gas pipe temp, liquid pipe temp, room temp, return air temp, inverter temp, and compressor body temp to name a few. There are many different thermistor ohm ratings, refer to your specific manufacturer’s literature for your temperature to resistance charts.\u00a0 Common ones are a 10k either ptc or ntc thermistors. <\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Protection Modes<\/span><\/span><\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Unlike traditional unitary systems, mini splits use many forms of protection control to prevent serious damage from occurring.\u00a0 Different manufacturers have different limits but generally speaking they\u2019re all looking at the same things.\u00a0 Some examples are:<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Low Pressure Protection<\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Once the unit gets below a certain suction pressure, the compressor will be commanded to slow down or maintain its current speed.\u00a0 There\u2019s a possibility you can get hung up in a low pressure step-down where it doesn\u2019t get high enough to allow it to try to ramp up again, so it will look to you as if the machine is just running at a low rps. <\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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High Pressure Protection<\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Once the unit hits a certain head pressure, compressor speeds will be limited and slowed down if needed to lower the discharge pressure.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Discharge Temperature Stepdown<\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Discharge pipe temperature step down occurs if the thermistor off of the discharge line of the compressor is too hot.\u00a0 This could mean any number of things but one of which could mean it\u2019s low on refrigerant.\u00a0 The machine is going to limit the compressor speed in an effort to save the compressor from being damaged.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Inverter Temperature Step<\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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If the temperature of the inverter board heatsink becomes too hot, inverter operation could be stopped, or compressor speed will slow down to prevent damage to the board.\u00a0 You could run into this if a board has recently been replaced and the heatsink paste was not applied during replacement. It\u2019s also imperative that all screws get replaced in the proper position or you will not get good contact on the heatsink and likely<\/span> overheating the board will occur.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Piping Diagrams<\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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This is a typical piping diagram shown in a service manual.\u00a0 These can be helpful tools in troubleshooting an issue.\u00a0 Note the red arrows indicate flow direction during heating operation and blue for cooling operation.\u00a0 Note that the upper line coming into the 4 way valve is always discharge gas, and the middle line coming out of the 4 way valve is always suction gas.\u00a0 Also note that this unit\u2019s EEV is located in the outdoor unit, meaning the lines leaving the outdoor unit are the expansion line and the gas pipe line.\u00a0\u00a0<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Tools Required<\/span><\/span><\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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If you are going to work on mini splits, there are a couple of items that you MUST HAVE.\u00a0 A good voltmeter that can read a high resistance is an ABSOLUTE MUST HAVE.\u00a0 Most thermistor values are 5-75K ohms.\u00a0 If you do not have a meter that\u2019s capable of reading that high of a resistance value, it will show you an OL even though the thermistor isn\u2019t actually open, rather it\u2019s just a value that\u2019s higher than what your meter is capable of reading.\u00a0 If you\u2019re unsure, check the spec sheet for your respective meter.\u00a0 Make sure you have a nitrogen regulator that is capable of 600 psig, that way the proper pressure test can be performed. Also having a good thermometer that\u2019s capable of reading pipe temperature is recommended. <\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Common Issues<\/span><\/span><\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Let\u2019s touch on a couple of things that could very well help you out if you are on a mini split call. <\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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1.) Leaking Flares<\/span>.  <\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Leaking flares are likely the most common cause for a service call and one of the easiest to avoid.\u00a0 Using a good sharp blade on your tubing cutter, deburring the copper, making a proper flare (using an orbital flaring tool with clutch), checking it with a flare gauge, and tightening it to the proper torque settings are the keys to avoid this from happening.\u00a0 Expansion and contraction put the flare under a huge amount of stress changing between modes.\u00a0 See Bryan\u2019s tech tip for more info.\u00a0 <\/span>https:\/\/www.hvacrschool.com\/making-flare-quick-tips\/<\/span><\/a><\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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2.) Communication Problems<\/span>.<\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Communication problems can stem from any number of things.\u00a0 Hit the basics first.\u00a0 Make sure your wiring terminations are correct as most use a 1, 2, 3 configuration.\u00a0 Ensure any external safety circuit wiring like a condensate overflow switch is wired properly, drains are clear, and condensate pumps are in working order.\u00a0 Generally speaking, most manufacturers use the 3<\/span>rd<\/span> wire plus one of the other high voltage conductors as a traveler wire (or common if you want to look at it that way).\u00a0 If you check between either 1->3 or 2-3 (again depending on manufacturer, refer to the manufacturer for specs) but typically you are going to be looking for a fluctuating DC voltage signal from 30-100 VDC.\u00a0 If you remove the 3<\/span>rd<\/span> wire from the outdoor unit and check for VDC coming from the outdoor unit and also from the indoor unit, you could narrow your work by seeing if there is one voltage that is not fluctuating.\u00a0 Continue to narrow your work until you can identify the issue or the failed component.\u00a0\u00a0<\/span><\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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3.) Refrigerant Leaks<\/span>.<\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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See #1 for the most common places to find refrigerant leaks.\u00a0 Improperly made and improperly tightened flares seem to account for a large majority of the refrigerant leaks.\u00a0<\/span><\/p>

How do I know if the machine is low on refrigerant? Good question.\u00a0 While superheat and subcooling on these can\u2019t tell you the whole story, don\u2019t discount the data you can gather from it.\u00a0 Find in the manual how the machine’s eevs are being controlled (see above explanation on how target superheat\/target subcooling is achieved).\u00a0 Once you have established that, it is possible to at least establish whether you are low or not.\u00a0 I will typically run the machine in full heat or full cool (whichever the conditions allow) then observe what the superheat is doing.\u00a0 Most machines seem to run between 4-10 degrees of suction superheat in both heating and cooling mode.\u00a0 Remember that in heating mode, the big line leaving the unit is actually discharge gas (so please don\u2019t call it the suction line cause it isn\u2019t), so you need to take your pipe temp exiting the outdoor coil to see what the suction superheat is.\u00a0 Once you\u2019ve established that it is low, it\u2019s best practice to pull the entire charge, pressure test, evacuate, and recharge.\u00a0 If a flare is \u201cloose\u201d, please just don\u2019t tighten it.\u00a0 Take it apart and remake it, it only takes a few minutes compared to it leaking again and getting a call back.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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4.) EEV Issues<\/span>.<\/span><\/span><\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Troubleshooting EEV issues can be very complicated.\u00a0 First you need to understand where to find the information on how to check them out.\u00a0 Refer to manufacturers published documents for the ratings of each type of EEV coil.\u00a0 Make sure you bring your needle leads or you\u2019ll break the plug.\u00a0 If the motor ohms out ok, then you should be able to check the voltage coming out of the board (typically 12 VDC) and verify the board is outputting the voltage. As the valve is driving, you\u2019ll see a pulsing of voltage so keep that in mind.\u00a0 If you don\u2019t see the pulsing voltage when the valve should be driving, consider looking at the board.\u00a0 There are numerous EEV donut magnets that can allow you to operate the valve body by hand (https:\/\/weatherallreps.com\/shop\/ols\/categories\/specialized-tools) .\u00a0 *******NOTE—-The board and the valve have no way of knowing if they are out of sequence so if you go moving the valve, you need to return it to a spot that the board will know where it is at startup.\u00a0 I suggest running it all the way closed then cycling the power to the machine.\u00a0 If this is not done, compressor failure can and will occur.************* Along with the EEV donut, there is also a hand held EEV driver that fits most manufacturers EEV plugs.\u00a0 This allows you to operate the EEV by hand.\u00a0 (<\/span>https:\/\/youtu.be\/xUVV80BcU1M<\/span><\/a> email <\/span>eevmatetech@gmail.com<\/span><\/a> for more info)\u00a0 EEV issues can show up in a starved coil (typical) or a flooded coil.\u00a0 Knowing how to effectively measure superheat will help you determine what you\u2019re dealing with.<\/span><\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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5.) Incoming Power Issues<\/span>.<\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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With all of the electronics in the outdoor unit, incoming power is less forgiving than their standard equipment counterparts.\u00a0 They are sensitive to voltage not within their specs in addition to surges.\u00a0 Check and see if the manufacturer has a recommended surge suppressor.\u00a0 Corrections to incoming power issues and surge protection are a must.\u00a0 Circuit boards do not like these items and they will not last if left uncorrected.\u00a0<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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6.) Condensate Pump Wiring.<\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Please follow manufacturers recommended wiring for the auxiliary contacts to shut down the unit in the event of an overflow situation.\u00a0 Most will break the communication wire, which in most instances is ok, but some indoor units have designated terminals and a plug for condensate overflow that should be used instead.\u00a0 Make sure if wiring to auxiliary terminals that you change the appropriate settings in the controls so the unit will operate correctly.\u00a0<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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7.) Use Appropriate Connectors.<\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Wire nuts for communication lines is not the best practice for joining communication wiring together. Butt splices, bell connector, terminal blocks, and soldered connections are superior methods. The use of wire nuts is a common problem waiting to happen and I would not recommend using them unless you like troubleshooting common problems.\u00a0<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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8.) Crossed Wiring\/Piping.<\/span><\/span><\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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This is a very common issue in multi splits.\u00a0 Installers, it is of the utmost importance that you color code\/mark your line sets as it\u2019s really easy to get them crossed up.\u00a0 If you happen to get them crossed up, any number of complaints can happen.\u00a0 The biggest one is overcooling or overheating of a space.\u00a0 Another one could be getting a condensate fault (especially if the unit has a condensate pump) as the condensate pump is only active when the unit is calling for cooling.\u00a0 If you suspect crossed wiring\/piping, run each head individually one by one verifying refrigerant is flowing to the unit that you want it to.\u00a0 Pick up some phase tape from your local hardware store or electrical supply in a number of colors, it could really save you down the road.\u00a0<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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In closing, stick to the basics.<\/strong>\u00a0 They really aren\u2019t as complicated as they appear to be.\u00a0 Remember that all circuit boards do is take inputs, apply logic, then produce an output.\u00a0 Remember that poor inputs will create poor output control.\u00a0 For those of you who are old school programming types will remember GIGO (garbage in and garbage out).\u00a0 If the input from say a thermistor is reading incorrectly, the output that it is responsible for controlling (EEV) will not modulate or control correctly.\u00a0 <\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

This article will be geared for HVAC techs who are new to mini splits.\u00a0 As the mini split market continues to grow, technicians face more and more challenges with these systems.\u00a0 The largest challenges would be the lack of training, and not having the proper tools to be effective working on them.\u00a0 Please go to […]<\/p>\n","protected":false},"author":1,"featured_media":17991,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[],"class_list":["post-21278","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"yoast_head":"\nMini Splits For New HVAC Techs - by Ryan Findley<\/title>\n<meta name=\"description\" content=\"Mini Splits For New HVAC Techs - by Ryan Findley. This article will be geared for HVAC techs who are new to mini splits.\" \/>\n<meta name=\"robots\" content=\"noindex, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Mini Splits For New HVAC Techs - by Ryan Findley\" \/>\n<meta property=\"og:description\" content=\"Mini Splits For New HVAC Techs - by Ryan Findley. 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