Re: the heat relay is closing on call for heat but...
Ok rheem and ruud is the only co that the hp is set to the b term on the stat for heat. is the stat wired corectly? is it a hp stat? and on a 2 1/2 ton hp you should have more than 5 kw. what kind of stat? the relay is correct because you have transformer that takes 208/230 down to 24 va. let me know.
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It is either the element, sequencer (or contactor/relay), or power to the switching element. 5KW Elements normally Ohm out @ around 10 Ohms when they are good. Everything you need to check requires a multimeter.
You can use the existing air handler for a heat pump condenser unit up to 3 tons. The line set, evap coil are fine for a heat pump. The electric heat strip issue can be another problem, you can put several different size strips in depending on what may be needed where you live, the power requirements will differ with each heat strip, for example a 5KW (5000 watt) heat strip requires a 2 pole 30 amp circuit for heat strip and air handler combination.
I would venture to say your stack relay is getting stuck. either that or you have a short in your low voltage wiring somewhere that is not always making contact....or it may be making contact through another median...like ice or frost. Remember electricity takes the path of least resistance.
But I would check the relay first. If its a stack relay or a closed type relay, try putting in a contactor that you can visually see if its closed or not.
In general, when more than one heat strip is present, one is used as primary heat, and the second one comes on if the primary does not prevent the temp from falling.
Another set up is, yes there can be a time delay in the system. it usually takes a few minutes for the second set to energize.
Since you did not state if this is a heat pump, i'm limited in my response at this time.
Hope this helps.
1. The units should match up without a problem.
2. You will need a 40 or 50 amp breaker for the A/H and 5 KW heat strip. You will probably need a 20 or 25 Amp for the condensing unit. I would check the FLA (full load amps) rating on both units, total them and install a breaker with no more than 20% more rating than the total. You can install a small box at the A/H with a breaker for the A/H and one for the condensing unit.
If you are getting the low voltage to the relay and it is not closing, then the relay may be either bad or stuck. Disconnect the 220v and see if the contacts can be manually closed. I always use a piece of wood or something non-conductive. If the contacts will close manually, try re--energizing the circuit to see if the relay will now close on its own. If not, you are probably looking at having to replace the relay switch. I had to replace mine last year. As always, be extremely careful working around electrical boxes and capacitors.
you may have lost your refrigerant and the unit is shut off on low pressure.
You can check the unit's charge by turning on the indoor fan and pushing the ourtdoor contactor down(the relay with heavy wires going in). With the unit runnig for a couple minuits does the large copper line coming into the outdoor unit from the indoor coil get cold to the touch?
If not you have lost your refrigerant
Hi!!! Does your ac unit work fine?If not check your low voltage problem..You have a low voltage problem check the wire going out to your condensor make sure that they are not touching..Good luck..Check low voltage wires..short in progress..