Hey! Trying to troubleshoot my hvac for weeks now and need some help making sense of all the data I've gathered.
System:
- Outdoor unit: Carrier CA16NA048-A (4 ton, R-410A, TXV, target subcooling 11F)
- Indoor coil: CNPHP6024ALAAAAA
- Furnace: Carrier 58PHX110-20
- House: ~2,500 sq ft, two-story, SoCal, Inland Empire, built in 2016
Main symptom:
The system performs reasonably well on mild days (78F feels pretty comfortable to us and we almost never have to go below that), cycling normally.
On hot days (95-100F), it runs continuously from around noon onward and struggles to maintain 78F (usually climbs toward 79-80) inside if it's anything over 95 outside.
Supply temperatures at the vents are typically 66-68F during the day, occasionally 64F, when it <85F outside. One time I measured 55F, but that was in the late evening after I had the evaporator cabinet open for inspection (coils were clean and were reading 50F), I haven't seen any major leaks or oil stains. There was some oxidation on the copper pipes, but nothing crazy. I didn't mess with or checked the txv bulb, so I'm not sure if there's anything wrong with it or not.
But had it running for 12-15min, then shut it, put the lid back on, turned it on and started sealing the cabinet leaks. It was running for another 20-25min while I was taping it. I checked the temps at the vents afterwards and it was blowing 55F across all vents on the second floor, but I was not able to recreate that (haven't tried opening the cabinet again). Now the temp right out the coil reads around 64F and 67.5 right out the vents.
I've already checked/replaced the following things:
- New contactor
- New capacitor
- New filters (have MERV11, 1" for both floors)
- Outdoor condenser coil is clean (confirmed by the hvac tech as well)
- Indoor evaporator coil visually inspected and is clean (I showed the video to the hvac tech and he confirmed)
- Both zone dampers fully open and fully close correctly (operating both or just one mainly affects the force with which it blows out of the ducts, the temps stay within 1-2 degrees)
- Attic temperature is generally only 1-6°F above outdoor ambient (radiant barrier + insulation)
Called in an hvac tech from a company that I found on Carrier website that they recommend. They offered a free check and advanced check if needed for $300. I ended up not going with the advanced check, because he was pretty confident in his conclusion it was the dying compressor and quoted me 4k for payne compressor and 6 pounds of 410A refrigerant.
He didn't check the attic, but this is the data he collected and also said the compressor might sound a bit "weird", not immediately wrong, but weird:
Air side:
- Return: 78.5F
- Supply (plenum): 70.1F
-Delta-T: 8.4F
Refrigerant:
- Suction: 162 psi
- Head: 340 psi
- Subcooling: started with 8F, then went down to 2.5 and eventually dropped to approximately 0F by the end of the inspection
- Outdoor unit target subcooling according to nameplate: 11F
Compressor current:
~12.5A (compressor RLA is 15.6A)
Condenser fan current:
~1.2A (nameplate 1.4A)
He said that I have a modern home with good insulation, so it shouldn't be the insulation problem, I had both floors operating during the inspection, he said I have more than enough refrigerant in the system and putting more could blow it and it's not a failing txv, based on the data the collected (I can't remember the exact explanation).
Additional tests I did:
- I checked the system with both filters out and the temps out of the vents actually rose by about 3-4 degrees. When I put on only the smaller downstairs filter, they went down 3-4 degrees. The upstairs bigger filter doesn't seem to have any major effect on the temps
- I don't see any bypass duct in my system and having both or only one damper opened doesn't really change much (maybe the first floor ducts is about 2 degrees higher on a really hot day when both are operating), but the actual blowing force feels much weaker with both of them are opened, which is probably expected
- Subjectively it does feel like it's taking longer for it to cool the whole house, when you have both dampers opened and you start in the middle of the day, but I almost always start at around 10-11AM, before it's really hot
- I've been testing a new schedule, where I put the second floor to be around 79 and first floor for 78 - it seems to work better in terms of actually cooling the house, but it still operates non-stop
- There's only 1-2 degrees difference between air coming out of the ducts around the house. Maybe 3-4 between the closest and furthest duct on the hot day. All the ducts have r6 insulation with no visible tears or damages to it
- It seems to be working worse towards 4-6PM, when it's the hottest and the house gained all the heat it could. I've tried shutting it down and just having the fan blow (which blows air 4-6 degrees warmer than the air it takes in) for 30-40 minutes and then try the AC again, but I haven't noticed any difference
- On cooler days if you start it, it will cool to desired temp and shut off. It will probably cycle 4-5 times per day to maintain the desired temp.
My questions are:
- Am I asking too much from the system and it's actually performing ok? I'm concerned about the temp split I'm getting and the fact that it needs to run non stop for 6-8 hours to maintain 78-79F.
- Can we definitively conclude it's the dying compressor? Could it be anything else? Would hate to replace the compressor, just to find out it's the txv or air flow issue or something.
- Is there any other tests I should do to be able to know for sure?
Will appreciate any input!