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Daikin DP 14, Service Instructions Manual

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Daikin DP 14 Service Instructions Manual Download Page 69

WIRING DIAGRAMS

69

HIGH VOLTAGE!
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS
UNIT.  MULTIPLE POWER SOURCES MAY BE PRESENT.  FAILURE TO
DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

DP14GM36***43A*

0140G04

4

53
-B

INS

TALLER/SE

R

VI

CE
M

A

N

-

GAS PRES

SURE

FLAME ROLLOUT

AU

X

. LIMIT OPEN

FLAME SENSOR

B

AD SWITCH

GAS VAL

V

E

CHE

C

K F

USE 

O

N

 C

O

N

T

R

O

L

CHE

CK INP

U

T

 POWE

R

REP

L

A

C

E

 C
O

N

T

R

O

L

GAS FLOW

A

N

T

I-C

YC
LE
 TI
M

E

R

MAIN LIMIT OPEN

STICKIN

G G

AS VA

LV
E

B

AD SWITCH

3 MIN. COMP.

PRESSURE SWITCH

PRESSURE SWITCH

CHECK

CHECK

OF
F

ON

OR

OR

1 BL

INK

3 BL

INKS

6 BL

INKS

2 BL

INKS

4 BL

INKS

5 BL

INKS

FALS

E

 FLAME S

ENSED

OUTPU

T DELAY

OP

EN LIMIT SWIT

C

H

COMPRES

SOR

WITHO

UT INDUCER ON

PRESSU

R

E S

W
IT

C

H

 CL
OSED

PRESSURE SWITCH

OP

EN AUX. LI

MI
T

OP

EN ROLLOUT

SWITCH

OPEN

SWITCH

IGNITION FAILURE

NORMAL OPERATION

NO POWER OR

INTERNAL CON

TROL

FAULT

STATUS LIGHT

EQUIP

. STATUS

CHECK

T

R

O

U

B

L

E

S

H

O

O

T

IN

G

 T

HIS 

A

P

P

L

IA

N

CE.  

S

T

AT
US 

LI

G

H

T 

C

O

DE
S AR

E 

AS 

F

O

L

L

O

W

S:

T

HE ST

A

TUS 

LI

G

H

T 

O

N

 T

HE 

F

U

R

N

A

CE 

C

O

N

T

R

O

L 

M

A

Y BE 

U

S

ED 

AS A 

G

UID

E TO

RD

PU

BK

BR

PU

BK

CM

C

O

NNE

C

TE
D A

T

 L1, L2

BK

BK

N

OTE 3

C

H

 OPT

IO

NAL

T2

T3

COMP

T1

RD

RD

WH

RD

PU

OR

RD

C

F

RD

WH

WH

YL

YL

SEE

N

O

TE 7

YL

WH

BL

BL

BL

BR

BR

RD

OR

BL

BL

BL

RD

RD

RD

RD

PU

WH

OR

RD

YL

YL

Y

 IG
N

FS

FC

PU

BL

BR

PU

RD

RD

YL

YL

RS

PU

PU

BL

VM

PU

L2

UNUS

ED

HEAT

FS

L1

DI

1

3

6

5

2

4

10

7

9

12

8

11

15

0

12

0

ECO

N

13

5

P1

F1

FUS

E 3

 AM

P M

A

X

P3

GR

RD

YL

WH

YL

YL

COM

PRE

SS

OR

COOL

SCR

EW

REQ

UIRE

D

P2

T1

MOU

NT

BREAK F

OR

 TW

O ST

AGE

SPEED-U

P

GR

WH

WH

GR

RD

C

RD

TO

 TH

E

R

M

O

S

T

A

T

ALS

PS

GV

MV

(AL

T

.)

HO

N

E

YW

E

L

L

GAS VALVE

GV

MV

GAS VALVE

W. R.

RS

IIC

HPS

YL

LS

L1

L2

CC

T1

T2

RD

BK

PU

BK

YL

RD

GND

PO

WE

R S

UPPL

Y

208

-230/3/60

C

H

 OPT

IO

NAL

SEE NO

TE 3

BK

BK

1

C

24V

BL

2

TR

3

240

3

4

2

1

RD

VM

R

BK

PU

PU

BL

PU

YL

208

N

O

TE 2

SEE NO

TE 6

RD

BK

BK

     OP

T

IONAL L

O

W V

O

L

TAGE

OP

T

IONAL HI

GH 

V

O

L

TAGE

     

F

IELD I

N

S

TALLED 

CO

NT
R

O

L

     
F

IELD I

N

S

TALLED P

OWE

R

NO

TES :

1. RE

P

L

ACE

M

ENT W

IRE 

M

UST BE TH

E SA

ME SI

ZE
 AND 

TYP

E

 OF

    I
NSUL

AT
IO

N 
AS OR

IG

INAL

.(USE

 CO

PPER C

ONDUCT

O

R 
ON

L

Y).

2. 
F

O

R 208 

V

OLT 

TRANS

FOR

MER 

OPER

A

T

ION M

OVE

 BLACK W

IRE

    FR

OM

 T

E

R

M

INAL

  3
  T
O

 TER

M

IN

AL
  2  

ON 

TRANS

F

OR

MER.

3. CRAN

KCASE

 HEA

TER NO

T 

SUPP

L

IE

D 
ON 

A

LL UN

IT

S

.

4. F

OR D

IFFEREN

T

 THAN 

FAC

T

O

RY
 SPEED 

TAP. CHAN

G

E

 CO

O

L

IN

G

    SPEED

 AT 

M

OTOR 

T

4

 AND 

T

5

 T

E

R

M

IN

AL
S. CHAN

G

E HEA

T

IN

G

    SPEED

 AT 

M

OTOR 

T

1

, T
2

 AND 

T

3

 T

E

R

M

IN

AL
S.

CO

O

L

ING

SPEED

 (Y
E

L

L

OW

 W
IRE)

 HEA

T

ING

SPEED

 (WH

ITE
 W
IRE)

      

         T

4

 - 

LOW

 SPEED 

   

           

            

            

       T

1

 - 

LOW

 SPEED

      

         T

5

 - H

IGH 

SPEED

   

         

          

            

           T

2

 - 

M

ED. 

SPEED

      

            

          

    
        

            

          

  

   

   

    

          

      T3 - H

IGH 

SPEED

5. US

E C

OOPER

 CONDUC

TORS

 ON

L

Y

6. L

1

 AND 

L2 ON

 II

C CON

TRO

L 

IS

 24V 

INPUT.

C

O

M

PO

NE
N

T

 LEGE

N

D

ALS           

 AU

X

ILLAR

Y LI

M

IT

 SWI

T

C

H

C   

             C

O

N

TAC

T

O

R

C

H

   

          CRA

NK
CASE HEA

TER

C

M

             C

O

N

D

E

NSE

R 
M

O

T

O

R

C

O

M

P

        

C

O

M

PRESSO

R

EM

             EVAPORA

T

O

R 
M

O

T

O

R

F

                

F

USE

F

C

   

           FA

N 
CAPACI

T

O

R

FS 

             F

L

AM

E SENSO

R

G

ND   

        E

QUIP

M

EN
T

 GR

OU

N

D

GV       

      

GAS VALVE

HPS      

     

HI
G

H

 P
RESSU

RE S

W
IT

CH

IIC 

             I

N

TEGRA

TED I

G

NI
T

ION 

C

O

N

T

R

O

L

IG
N   

         IGNI

T

OR

LS              LIM

IT

 SWI

T

C

H

PLF

-A  

       FE

M

ALE PLU

G/C

ON

NE
CT
O

R

 ALS

PLM

-A  

      

FE
M

ALE PLU

G

/C
O

N

NE
CT
O

R

 ALS

PS             

 PRESSU

RE S

W
IT

C

H

RS     

         R

O

LL
O

U

T

 SWI

T

C

H

T

R

   

           T

R

A

N

S

F

O

R

M

E

R

VM

             VEN

T

 M
O

T

O

R

VM

R   

        VE

NT
 M
O

T

O

R RELA

Y

PU 

-  PURPLE

YL  

- YE

LLO

W

W
H

 - 

 W
H

IT

E

R

D

 -  RED

BL  -

 BLUE

BR -

 BR
O

W
N

G

R

 -

  G
REE

N

OR -

  O

R

A

N

GE

PK -   PI

NK

WI
RE

C

O

DE

BK  - BLA

CK

     LOW V

O

L

T

A

G

E

WI
RI
N

G

     

HI
G

H

 VOL

TAGE

USE  N

EC C

LASS 2 

WI
RE.

208-230/

3

/6

0

BL

YL

RD

GR

WH

N

O E

C

O

N

O

M

IZE
R

W

Y

C

R

G

T

H

E

R

M

OSTAT

 F

IELD 

WI
RI
NG

BL/PK - BL

UE/PI

N

K

YL

24 V

H

C

EM

RG

W

Y

T

O

 THERMOSTA

T

11

C

4

II

C

ECO
N

9

7

8

10

12

6

5

3

FS

F

L1

PS

ALS

RS

LS

GV

FS

IG
N

VM

L2

SUPPL

Y

 V

OLTAGE

1

T1

COMP

T3

C

T1

T2

L1

C

CM

208

-230/3/60

T2

CH

2

L2

N

OTE 3

TR

C

D1

C

13

EM

VM

R

VMR

2

N

OTE 6

NO

TE 6

T4

T3

L

N

3

2

1

II

C

T5

2

T1

T

C

F

N

OTE 2

4

HPS

N

O

TE 4

C

T1
T2
T3
T4
T5

LGN

EM

WH

YL

GR

PU

BL

BK

1

2

1

2

RD

BL

BL

PU

PLM-A

PLF-A

YL

BL

BL

BL

L3

T3

L3

C

T3

FC

7

4

1

3

2

8

9

5

6

7

4

1

3

2

8

9

5

6

RD

RD

RD

GR

GR

YL

YL

YL

YL

BL

BL

Summary of Contents for DP 14

Page 1: ...A 2 3 Central Furnaces Service Instructions DP 14 SEER Gas Electric Package Units with R 410A Refrigerant Accessories This manual is to be used by qualified professionally trained HVAC technicians only Daikin does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person Copyright 2014 2017 ...

Page 2: ...pment HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may cause property damage personal injury or death IMPORTANTINFORMATION 2 3 PRODUCTIONIDENTIFICATION 4 5 ACCESSORIES 6 14 PRODUCT DESIGN 15 20 SYSTEM OPERATION 21 28 SCHEDULEDMAINTENANCE 29 31 TROUBLESHOOTING CHARTS 32 33 SERVICING TABLE OF CONTENTS 34 SERVICING 3...

Page 3: ... rating meets or exceeds 400 lbs When in doubt do not use cylinder WARNING The compressor POE oil for R 410A units is extremely susceptible to moisture absorption and could cause compressor failure Do not leave system open to atmosphere any longer than necessary for installation WARNING In either of these instances an electrical short between the terminal and the compressor housing may result in t...

Page 4: ... P Packaged Major revision SEER Voltage 14 SEER 1 208 230 V single phase 60 Hz 2 220 240 V single phase 50 Hz Unit Type 3 208 230 V three phase 60 Hz G Gas Electric 4 460 V three phase 60 Hz D Dual Fuel 5 380 415 V three phase 50 Hz Configuration Refrigerant M Multi position 4 R 410A H Horizontal Nominal Heat Input Tonnage Nominal 040 40 MBTU H 100 100 MBTU H 24 2 ton 42 3 5 ton 060 60 MBTU H 120 ...

Page 5: ...n Brand Package Gas Multi Position 14 Seer R410A gas electric unit Release of models with W hite Rodgers gas valves DP14GM61 41AA Daikin Brand Package Gas Multi Position 14 Seer R410A gas electric unit Release of 5 ton models with a compressor change DP14GM 36 60 43AA Daikin Brand Package Gas Multi Position 14 Seer R410A gas electric unit Initial release of three phase models Single Phase Package ...

Page 6: ...assis with economizer DDNIFRPGML Downflow Internal Filter Rack for M Series Gas Package Unit Large Chassis with economizer DDNIFRPGA Downflow Internal Filter Rack for M Series Gas Package Unit no economizer DHZ25FDPGCHMM Manual 25 M Series Fresh Air Damper Horizontal Application Medium Chassis DHZ25FDPGCHML Manual 25 M Series Fresh Air Damper Horizontal Application Large Chassis DHZ25MFDPGCHMM Mot...

Page 7: ...and which cause cancer birth defects or other reproductive harm are known to the This product contains fiberglass insulation State of California to product could expose California to cause known by the State of contains a chemical Fiberglass insulation cancer 0140F01902 A call a qualified service technician will not operate don t try to repair it gas Then smell for gas including near the floor If ...

Page 8: ...hnician to inspect D Do not use this appliance if any part has been underwater or explosion technician Force or attempted repair may result in a fire hand don t try to repair it call a qualified service Never use tools If the lever will not push in or turn by C Use only your hand to push in or turn the gas control lever call the fire department If you cannot reach your gas supplier phone Follow th...

Page 9: ...PGCHMA 46 1 4 39 3 8 14 1 2 12 1 2 x 23 15 x 22 1 2 ROOF CURBS Filter Size 14 x 25 x 2 Measurement in inches 26 1 2 14 25 3 2 1 1 2 DOWNFLOW FILTER RACK DDNIFRPGA NOTE DDNIFRPGA cannot be used with downflow economizers B S R C 1 5 8 14 1 2 1 3 8 A ...

Page 10: ...10 DPHFRA EXTERNAL HORIZONTAL FILTER RACK 16 x 25 x 2 FILTER ...

Page 11: ... 20 MIST ELIMINATOR 14 X 25 FILTER ATTACHMENT A B 16 18 DDNECNJPGML DDNECNJPGML DOWNFLOW ECONOMIZER DDNECNJPGMM DOWNFLOW ECONOMIZER PGED101 102 A B C D E F 20 16 25 16 23 5 12 5 45 75 B A F D E C A B C D E F 20 16 25 16 23 5 12 5 45 75 DDNECNJPGMM ...

Page 12: ... 5 3 4 11 7 8 MOTORIZED MANUAL FRESH AIR DAMPERS HORIZONTAL APPLICATIONS MODEL A B C D E FILTER DHZECNJPGCHM 25 1 4 18 1 8 18 13 3 4 16 1 8 16 x 25 x 1 DHZECNJPGCHL 35 1 4 18 1 8 18 18 1 4 16 1 8 16 x 25 x 1 ECONOMIZER HORIZONTAL APPLICATIONS Measurement in inches D E C A B 18 16 1 8 A B 31 1 2 29 3 4 30 29 3 4 A B 31 1 2 29 3 4 30 29 3 4 DHZ25MFDPGCHML MOTORIZED MANUAL DHZ25FDPGCHMM DHZ25FDPGCHML...

Page 13: ...ODEL A B C D RETURN SUPPLY SQRPG101 102 22 3 4 12 1 4 22 1 4 14 3 4 16 16 SQRPG103 22 3 4 12 1 4 22 1 4 14 3 4 18 18 MODEL A B DDN25FDPGCHMM 16 16 DDN25FDPGCHML 18 16 MODEL A B DDN25MFDPGCHMM 16 16 DDN25MFDPGCHML 18 16 MANUAL MOTORIZED MOTORIZED MANUAL FRESH AIR DAMPERS DOWNFLOW APPLICATIONS 10 12 1 8 6 1 10 12 1 8 6 1 5 3 4 5 3 4 BOTTOM VIEW BOTTOM VIEW DDN25FDPGCHML DDN25FDPGCHMM 11 7 8 11 7 8 ...

Page 14: ...ACCESSORIES 14 A C B SQUARE TO ROUND CONVERTER HORIZONTAL APPLICATIONS Measurements are in inches MODEL A B C SQRPGH101 102 16 16 1 2 16 1 2 SQRPGH103 18 18 1 2 18 1 2 ...

Page 15: ...DEQUATE CABLE SLIDE NOTE A roof curb can be used to utilize bottom discharge DPGMPackageUnitsaredesignedforoutdoorinstallations only in either residential or light commercial applications NOTE To ensure proper condensate drainage unit must be installed in a level position The connecting ductwork Supply and Return can be con nected for either horizontal or down discharge airflow In the downdischarg...

Page 16: ...erant NOTE Eventhoughthe compressor section of a Scroll compressor is more tolerant of liquid refrigerant continued flood back or flooded start conditions may wash oil from the bearing surfacescausingprematurebearingfailure These Scroll compressors use POE or polyolester oil which is NOT compatible with mineral oilbased lubri cants like 3GS POE oil must be used if additional oil is required Compli...

Page 17: ... unit control box GAS SUPPLY AND PIPING CAUTION THIS PACKAGE GAS UNIT IS FACTORY SET TO OPERATE ON NATURAL GAS AT THE ALTITUDES SHOWN ON THE RATING PLATE IF OPERATION ON PROPANE IS REQUIRED OBTAIN AND INSTALL THE PROPER CONVERSION KIT S BEFORE OPERATING THIS UNIT FAILURE TO DO SO MAY RESULT IN UNSATISFACTORY OPERATION AND OR EQUIPMENT DAMAGE The rating plate is stamped with the model number type o...

Page 18: ...as the equipment NOTE In b and c the connector or tubing must be installed so as to be protected against physical and thermal damage Aluminum alloy tubing and connectors must be coatedtoprotectagainstexternalcorrosionwheretheyarein contact with masonry plaster or insulation or are subject to repeated wettings by such liquids as water except rain water detergents orsewage DRIP LEG MANUAL SHUT OFF V...

Page 19: ...cond Stage Regulator First Stage Regulator WARNING PROPANE TANK SIZING MINIMUM TANK SIZE REQUIRED IF LOWEST OUTDOOR MAXIMUM GAS TEMPERATURE AVG FOR 24 HOURS REACHES NEEDED TO VAPORIZE 32 F 20 F 10 F 0 F 10 F 20 F 30 F 125K BTU HR 50 CFH 115 GAL 115 GAL 115 GAL 250 GAL 250 GAL 400 GAL 600 GAL 250K BTU HR 100 CFH 250 GAL 250 GAL 250 GAL 400 GAL 500 GAL 1000 GAL 1500 GAL 375K BTU HR 150 CFH 300 GAL 4...

Page 20: ...rtion of the liquidimmediatelyvaporizes Itcontinuestosoakupheatand vaporizes as it proceeds through the coil cooling the indoor coil down to about 48 F Heatiscontinuallybeingtransferredtothecoolfinsandtubes of the indoor evaporator coil by the warm system air This warming process causes the refrigerant to boil The heat removed from the air is carried off by the vapor As the vapor passes through th...

Page 21: ...l for heatshallproceedasnormalexceptthefanremainsenergized on cool speed Heat Mode 1 CALL FOR HEAT The thermostat calls for heat by energizingthe W terminal Thecontrolcheckstosee if the pressure switch is open If the pressure switch is closed the control will flash code 3 on the LED and wait indefinitely for the pressure switch to open The control will lockout the call for heat if the pressure swi...

Page 22: ...ble 120 135 or 150 Seconds Cool ON Delay 7 Seconds Cool OFF Delay 60 Seconds Ignition Attempts 3 Attempts Recycles Infinite 4 Recycles 5 Flame Losses Automatic Restart 60 Minutes Compressor Short Cycle Delay 3 Minutes System Status LED Flashes Normal On Internal Fault Gas Valve Fault Off Ignition Lockout 1 Pressure Switch Stuck Open 2 Pressure Switch Stuck Closed 3 Open High Temperature Limit 4 Fl...

Page 23: ...rmostat request B HeatingOperation Highstageheat 1 Thermostat type is set to two stage 2 Thermostat W1 and W2 inputs initiate high stage heating 3 Induceddraftblowerisenergizedathighspeedforthe pre purgeperiod Pre purgetimerbeginsaftercontrol recognizes pressure switch has closed 4 Trial for ignition period begins after pre purge period expires Lowandhighstagegasvalvesareenergized alongwiththeigni...

Page 24: ...tage cooling IDT ODT Pressure Loss of Charge Switch circuits are checkedforclosedcondition Coolingoperationcanproceed only if these circuits are closed 1 Low and high stage compressor outputs are ener gized 2 Condenser fan motor is energized at high speed 3 Air circulating blower is energized at high cool speed after cool ON delay expires Cool ON delay timer begins when thermostat inputs are detec...

Page 25: ...t 5 fault codes To recall the fault codes depress the fault recall but ton for at least 2 seconds but not more than 4 seconds To clear the fault code memory depress the fault recall button for at least 5 seconds The following tables list the functions for the connectors and terminals the timings and the fault codes for the PCBAG127 control board HIGH VOLTAGE Disconnect ALL power before servicing o...

Page 26: ...used 5 24VAC 24VAC Common 6 24VAC Pressure Switch Output 7 24VAC Main Valve High Output 8 24VAC Pressure Switch Input 9 Unused Main Valve Low Output Table 2 Circuit Definitions and Voltage Ratings for the 9 Circuit Connector Circuits Terminal Label Line Voltage L1 L1 Transformer Line L1 L1 Air Circulating Blower Line 1 L1 Induced Draft Blower Low Speed DI Low or Inducer Low Induced Draft Blower Hi...

Page 27: ... OFF Delay 0 Seconds Ignition Attempts 3 Recycles Infinite Automatic Restart 60 Minutes Pressure Switch Lockout Delay 5 Minutes Factory Test Mode Active Time 2 Minutes Maximum Flame Failure Response Time Table 4 Control Timings Color Function LED Flashes Status Normal On Intrnal Gas Valve Fault Off Lockout 1 Pressure Switch Stuck Open 2 Pressure Switch Stuck Closed 3 Open High Temperature Limit 4 ...

Page 28: ... RestrictorOrificeAssemblyinCoolingOperation In the cooling mode the orifice is pushed into its seat forcing refrigerant to flow through the metered hole in the center of the orifice Either a thermostatic expansion valve or restrictor orifice assembly may be used depending on model refer to the parts catalog for the model being serviced ...

Page 29: ...etc Inspect all burners for lint and proper positioning 9 Startthesystem usingtheproperinstrumentationcheck gas inlet and manifold pressures burner flame and microamp signal Adjust if necessary 10 Start the system and run a Heating Performance Test If the results of the test are not satisfactory see the ServiceProblemAnalysis Guideforthepossiblecause TEST EQUIPMENT Proper test equipment for accura...

Page 30: ...514 1286 40 22 45 90 180 450 15 60 120 240 480 1200 41 176 439 16 56 113 225 450 1125 42 21 43 86 172 429 17 53 106 212 424 1059 43 167 419 18 50 100 200 400 1000 44 41 82 164 409 19 47 95 189 379 947 45 20 40 80 160 400 20 45 90 180 360 900 46 78 157 391 21 43 86 171 343 857 47 19 38 76 153 383 22 41 82 164 327 818 48 75 150 375 23 39 78 157 313 783 49 147 367 24 37 75 150 300 750 50 18 36 72 144...

Page 31: ...HAN PLUS OR MINUS 3 INCHES WATER COLUMN FROM 3 5 INCHES WATER COLUMN FOR NATURAL GAS OR 10 INCHES WATER COLUMN FOR PROPANE GAS To adjust the pressure regulator on the gas valve turn down clockwise toincreasepressureandinput andout counter clockwise to decrease pressure and input Sincepropanegasisnotnormallyinstalledwithagasmeter clocking will be virtually impossible The gas orifices used with prop...

Page 32: ...st Ignition Control S 313 Open Control Circuit Test Control Circuit w ith Voltmeter S 4 Low Voltage Test Voltage S 1 Faulty Evap Fan Motor Repair or Replace S 16 Shorted or Grounded Fan Motor Test Motor Windings S 16 Improper Cooling Anticipator Check resistance of Anticipator S 3 Shortage of Refrigerant Test For Leaks Add Refrigerant S 103 Restricted Liquid Line Replace Restricted Part S 112 Dirt...

Page 33: ...r Test Flame Sensor S 314 Faulty Ignition Control Test Control S 313 Gas Valve or Gas Supply Shut Off Turn Valves to On Position S 304 Faulty Induced Draft Blow er Test Blow er S 303 Dirty Flame Sensor Low uA Clean Flame Sensor S 314 Flame Sensor not in Flame Low uA Test Adjust Position of Flame Sensor S 314 Faulty Gas Valve Replace Gas Valve S 304 No High Stage Heat 2 Stage Only Check Thermostat ...

Page 34: ...roundTest 42 S 17D OperationTest 42 S 18 Testing Crankcase Heater optional item 43 S 100 RefrigerationRepairPractice 43 S 101 LeakTesting 43 S 102 Evacuation 44 S 103 Charging 45 S 104 CheckingCompressorEfficiency 45 S 105B ThermostaticExpansionValve 45 S 106 Overfeeding 47 S 107 Underfeeding 47 S 108 Superheat 47 S 109 CheckingSubcooling 49 S 110 CheckingExpansionValveOperation 49 S 111 Fixed Ori...

Page 35: ...hin the voltage tabulation as shown If the voltage falls below the minimum voltage checkthelinewiresize Longrunsofundersizedwirecan causelowvoltage Ifwiresizeisadequate notifythelocal power company in regards to either low or high voltage Voltage Min Max 460 437 506 208 230 198 253 Unit Supply Voltage Three phase units require a balanced 3 phase power supply to operate If the percentage of voltage...

Page 36: ... 3 No voltage indicates the trouble is in the thermostat or wiring 4 Checkthecontinuityofthethermostatandwiring Repair or replace as necessary S 3B COOLING ANTICIPATOR The cooling anticipator is a small heater resistor in the thermostat During the off cycle it heats the bimetal element helping the thermostat call for the next cooling cycle This prevents the room temperature from rising too high be...

Page 37: ...may cause property damage personal injury or death The compressor contactor and other relay holding coils are wired into the low or line voltage circuits When the control circuit is energized the coil pulls in the normally open contacts or opens the normally closed contacts When the coil is de energized springs return the contacts to their normalposition NOTE Most single phase contactors break onl...

Page 38: ...onScrollcompressor equippedunitsduetoanon replaceablecheckvalvelocated in the discharge line of the compressor However hard start kits are available and may improve low voltage starting characteristics Thischeckvalveclosesoffhighsidepressuretothecompres sor after shut down allowing equalization through the scroll flanks Equalization requires only about one or two seconds during which time the comp...

Page 39: ... the start capacitor and the relay holding coil is wired parallel with the start winding As the motor starts and comes up to speed the increase in voltage across the start winding will energize the start relay holding coil and open the contacts to the start capacitor Two quick ways to test a capacitor are a resistance and a capacitance check S 15A RESISTANCE CHECK HIGH VOLTAGE Disconnect ALL power...

Page 40: ...he 5 pin and the 16 pin connectors from the ECM power head 2 Removethe2screwssecuringtheECMpowerheadand separate it from the motor 3 Disconnect the 3 pin motor connector from the power head and lay it aside 4 Using an ohmmeter check the motor windings for conti nuity to ground pins to motor shell If the ohmmeter indicates continuity to ground the motor is defective and must be replaced 5 Using an ...

Page 41: ...r and cannot occur externally fromtheventingterminalwithoutthepresenceofanexternal ignition source Therefore properevacuationofahermeticsystemisessen tial at the time of manufacture and during servicing To reduce the possibility of external ignition all open flame electrical power and other heat sources should be extin guished or turned off prior to servicing a system S 17A RESISTANCE TEST Each co...

Page 42: ...UND TEST 3 If a ground is indicated then carefully remove the com pressor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires 4 Ifnovisualproblemsindicated carefullyremovetheleads at the compressor terminals WARNING Damage can occur to the glass embedded terminals if the leads are not properly removed This can result in terminal and hot oil discharging Care...

Page 43: ...h dry nitrogen to prevent the formation of oxides on the inside surfaces 6 Completeanyrepairbyreplacingtheliquidlinedrierinthe system evacuate and charge BRAZING MATERIALS Copper to Copper Joints Sil Fos used without flux alloy of 15 silver 80 copper and 5 phosphorous Recom mendedheat1400 F Copper to Steel Joints Silver Solder used without a flux alloyof 30 silver 38 copper 32 zinc Recommended hea...

Page 44: ...ifold set with high vacuum hoses thermocouple vacuum gauge and charging cylinder as shown 2 Startthevacuumpumpandopentheshutoffvalvetothe high vacuum gauge manifold only After the compound gauge lowside hasdroppedtoapproximately29inches of vacuum open the valve to the vacuum thermocouple gauge See that the vacuum pump will blank off to a maximum of 25 microns A high vacuum pump can only produce a ...

Page 45: ...mpressors are inherently more tolerantofliquidrefrigerant NOTE Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant continuedfloodbackorfloodedstartconditionsmaywashoil fromthebearingsurfacescausingprematurebearingfailure S 104 CHECKING COMPRESSOR EFFICIENCY The reason for compressor inefficiency is broken or damaged scroll flanks on Scroll compressors r...

Page 46: ... 60 8 6 162 0 57 0 264 0 87 4 366 0 110 4 468 0 129 0 600 0 149 0 62 10 0 164 0 57 7 266 0 87 9 368 0 110 8 470 0 129 3 604 0 149 5 64 11 3 166 0 58 4 268 0 88 4 370 0 111 2 472 0 129 7 608 0 150 1 66 12 6 168 0 59 0 270 0 88 9 372 0 111 6 474 0 130 0 612 0 150 6 68 13 8 170 0 59 8 272 0 89 4 374 0 112 0 476 0 130 3 616 0 151 2 70 15 1 172 0 60 5 274 0 89 9 376 0 112 4 478 0 130 7 620 0 151 7 72 1...

Page 47: ...r during system repair or final unit disposal 1 Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on suction large line nearcompressor withadequatecontactandinsulatefor best possible reading 3 Refer to the superheat table provided for proper system superheat Add charge to lower superheat or recover charge to raise superheat Superheat Formula Suct Line ...

Page 48: ...9 88 86 84 82 80 78 308 90 88 86 84 82 80 317 92 90 88 86 84 82 326 94 92 90 88 86 84 335 96 94 92 90 88 86 345 98 96 94 92 90 88 354 100 98 96 94 92 90 364 102 100 98 96 94 92 374 104 102 100 98 96 94 384 106 104 102 100 98 96 395 108 106 104 102 100 98 406 110 108 106 104 102 100 416 112 110 108 106 104 102 427 114 112 110 108 106 104 439 116 114 112 110 108 106 450 118 116 114 112 110 108 462 1...

Page 49: ...esuctiontempera ture will fall 4 If a temperature or pressure change is noticed the expansionvalveisoperating Ifnochangeisnoticed the valve is restricted the power element is faulty or the equalizer tube is plugged 5 Capture the charge replace the valve and drier and evacuate S 111 FIXED ORIFICE RESTRICTOR DEVICES Thefixedorificerestrictordevice flowrator usedinconjunc tion with the indoor coil is...

Page 50: ...bles are removed from the system by first removing the refrigerant charge replacing and or installing liquid line drier evacuating and recharging S 115 COMPRESSOR BURNOUT When a compressor burns out high temperature develops causing the refrigerant oil and motor insulation to decom pose forming acids and sludge If a compressor is suspected of being burned out attach a refrigeranthosetotheliquidlin...

Page 51: ...ic pressure of the return duct at the inlet of the unit NegativePressure RETURN SUPPLY INCLINED MANOMETER Total External Static 2 Measurethestaticpressureofthesupplyduct Positive Pressure 3 Add the two readings together NOTE Bothreadingsmaybetakensimultaneouslyandread directly on the manometer if so desired 4 Consult proper table for quantity of air If the external static pressure exceeds the mini...

Page 52: ...ath 1 Remove electrical power to unit Some units may have more than one source of power 2 Remove the wires from the limit control terminals 3 Using an ohmmeter test for continuity across the two terminals 4 If limit test open allow unit to cool and retest 5 If still open replace the control S 301 TESTING AUXILIARY LIMIT The auxiliary limit control is a preset nonadjustable control mounted in the b...

Page 53: ...he control goes through a pre purge period and then makes an ignitionattempt Theindoorblowerremainson forthedelay off time during the re ignition attempt 1 If no voltage is measured on either side of control it indicates ignition control or wiring to control problem 2 If voltage is measured on one side of the control and not the other it indicates the control is open 3 If voltage is measured on bo...

Page 54: ...els Atwo stagecombinationredundantoperatortypegasvalve which provides all manual and automatic control functions requiredforgasfiredheatingequipmentisusedon15SEER models Thevalveprovidescontrolofmainburnergasflow pressure regulation and 100 percent safety shut off HIGH VOLTAGE Disconnect ALL power before servicing or installing this unit Multiple power sources may be present Failure to do so may c...

Page 55: ...consumed Theonlytimeresizingisrequirediswhenareductioninfiring rate is required for an increase in altitude Orifices should be treated with care in order to prevent damage They should be removed and installed with a box end wrench in order to prevent distortion In no instance should an orifice be peened over and redrilled This will change the angle or deflection of the vacuum effect or entraining ...

Page 56: ...d turn on all other gas consumingappliances ForNATURALGAS a Inlet pressure should be a nominal 7 w c b 2 stage heat models only Manifold pressure on low stage should be 2 0 w c 3 w c c Manifoldpressurefor1stageheatmodelsandhigh stage for 2 stage heat models should be 3 5 3 w c ForPROPANEGAS a Inlet pressure should be a nominal 11 w c b 2 stage heat models only Manifold pressure on low stage should...

Page 57: ...before the induced draft blower is energized the LED will flash a code of 2 to indicate the pressure switch is stuck closed and the inducer will remain off until the pressure switch opens If the pressure switch opens before the ignition period the induced draft blower will remain on and the control will stay in pre purge until the pressure switch is closed for an entire 15secondpre purgeperiod The...

Page 58: ...49 57 49 57 CANADA BURNER ORIFICE 48 56 ELEVATION ABOVE SEA LEVEL FEET 20 000 BTUH NAT 18 OOO BTUH LP INPUT BURNER HIGH ALTITUDE KIT HA 03 S 313 TESTING IGNITION CONTROL MODULE NOTE Failure to earth ground the unit or a high resistance connection in the ground may cause the control to lockout due to failure to flame sense TestingDirectSparkIgnition DSI systems Thermostat calling for heat 15 second...

Page 59: ...alve LED Flashes Status System Condition Off Internal Control Fault Micro Controller Detected Hardware Failure or Gas Valve Detected Energized W hen it Should be De energized 1 Lockout Due to Excessive Retries 2 Pressure Switch Stuck Open 3 Pressure Switch Stuck Closed 4 Open High Temperature Limit 5 Flame Present Outside the Flame Detect Mode 6 Compressor Short Cycle Delay Active 7 Limit Opened F...

Page 60: ...ting cycle 6 As soon as flame is established a microamp reading shouldbeevidentonceproofofflame microampreading is established the hot surface ignitor will be de ener gized 7 The nominal microamp reading is 4 microamps 8 If the microamp current is less than 0 5 microamp the control will lockout and flash a code of 1 flash after attempting to reestablish flame sense 9 If the microamp reading is les...

Page 61: ...06 500 48926 002 ORANGE 1 X 78 GROUND 1 X 50 COLOR CODES FOR PLUG 1 8 O ORANGE GROUND G GREEN WIRE LENGTHS FOR PLUG 1 9 8 7 3 2 1 G Y2 TSTAT Y1 CONTACTOR COMMON Y1 TSTAT O 6 5 4 CC1 Y Y2 CONTACTOR CC2 1 P PURPLE Y YELLOW 4 1 2 6 5 4 1 2 6 5 Y1 Y2 W2 R G C Y1 Y2 W2 R G C COOL 1 HEAT FAN ECON PLUG PLUG ECON GMC TERMINAL BLOCK ROOM THERMOSTAT 8 8 O O RV RV REVERSING VALVE ENERGIZED IN COOLING MODE 3 ...

Page 62: ...R BR RD OR BL BL BL RD RD RD RD PU WH OR RD YL YL Y IGN FS RCCF PU BL BR PU RD RD YL YL RS PU PU BL VM PU L2 UNUSED HEAT FS L1 DI 1 3 6 5 2 4 10 7 9 12 8 11 150 120 ECON 135 P1 F1 FUSE 3 AMP MAX P3 GR RD YL WH YL YL COMPRESSOR COOL SCREW REQUIRED P2 T1 MOUNT BREAK FOR TWO STAGE SPEED UP GR WH WH GR RD C RD TO THERMOSTAT ALS PS GV MV ALT HONEYWELL GAS VALVE GV MV GAS VALVE W R RS IIC HPS YL LS L1 L...

Page 63: ...AS FOLLOWS THE STATUS LIGHT ON THE FURNACE CONTROL MAY BE USED AS A GUIDE TO OPTIONAL LOW VOLTAGE OPTIONAL HIGH VOLTAGE FIELD INSTALLED CONTROL FIELD INSTALLED POWER COMPONENT LEGEND ALS AUXILLARY LIMIT SWITCH C CONTACTOR CH CRANKCASE HEATER CM CONDENSER MOTOR COMP COMPRESSOR EM EVAPORATOR MOTOR F FUSE FS FLAME SENSOR GND EQUIPMENT GROUND GV GAS VALVE HPS HIGH PRESSURE SWITCH IIC INTEGRATED IGNITI...

Page 64: ... BL BR BR RD OR BL BL BL BL RD RD RD RD PU WH OR RD YL YL Y Y2 IGN FS RCCF PU BL BR PU RD RD YL YL RS PU PU BL VM PU L2 UNUSED HEAT FS L1 DI 1 3 6 5 2 4 10 7 9 12 8 11 150 120 ECON 135 P 1 F1 FUSE3 AMP MAX P3 GR RD YL WH YL YL COMPRESSOR COOL SCREW REQUIRED P2 T1 MOUNT C 22 T2 BREAKFOR TWO STAGE S P EE D U P GR WH WH GR BL RD C RD TO THERMOSTAT ALS PS GV MV ALT HONEYWELL GAS VALVE GV MV GAS VALVE ...

Page 65: ... TYPE OF INSULATION AS O RIGINAL USE COPPER CONDU CTOR ONLY 2 FOR 208 VOLT TRANSFORMER OPERATION MOVE BLACK WIRE F ROM TERMINAL 3 TO TERMINAL 2 O N TRANSFORMER 3 C RANKCASE HEATER NOT SUPPLIED ON ALL U NITS 4 FOR DIFFERENT THAN FACTORY SPEED TAP CHA NGE COOLING SPEED AT MOTOR T4 AN D T5 TERMINALS CHA NGE HEATING SPEED AT MOTOR T1 T2 AN D T3 TERMINALS COOLING SPEED YELLOW WIRE HEATING SPEED WH ITE ...

Page 66: ... INDUCER L2 BK YL RD GR SEE NOTE 3 EM 208 PU YL PU BK N G L T5 T4 T3 T2 T1 240 3 TR 2 RD 24V C 1 YL BL 208 230 1 60 POWER SUPPLY GND C PU PU RD BK BR PU BK R S COMP C T2 T1 CC L2 L1 ALS CM LPS HPS PARK BK PU SEE NOTE 3 BL BK SEE NOTE 2 YL YL YL YL YL YL YL YL YL PU F WH BR YL BL OR OR YL PU BR BL BR PU PU YL NONE 5 MIN 10 MIN 180 150 120 90 Y2 Y1 G 1 W 2 W C R BLOW ER OFF DELAY STAGE DELAY ECON LO...

Page 67: ...I M RS PS LS ALS TR EM VM H F RCCF C L2 T2 208 230 1 60 CM L1 R T1 S COMP C L1 SUPPLY VOLTAGE P1 INTEGRATED IGNITION CONTROL CC CC COM HLI SEE NOTE 2 INTERGRATED IGNITION CONTROL F Y1 R C Y2 W2 W1 TO MICRO TO MICRO INTEGRATE D IGNITION CONTROL L1 LO L2 L2 L2 L2 SOL ODF OUTDOOR FAN HPS LPS 1 2 3 HIGH PRESSURE SWITCH HPS LPS LOW PRESSURE SWITCH EQUIPMENT GROUND FIELD GROUND FIELD SPLICE SWITCH TEMP ...

Page 68: ... 3 BK BK 1 C 24V BL 2 TR 3 240 3 4 2 1 RD VMR BK PU PU BL PU YL 208 NOTE 2 SEE NOTE 6 RD BK BK OPTIONAL LOW VOLTAGE OPTIONAL HIGH VOLTAGE FIELD INSTALLED CONTROL FIELD INSTALLED POWER NOTES 1 REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE OF INSULATION AS ORIGINAL USE COPPER CONDUCTOR ONLY 2 FOR 208 VOLT TRANSFORMER OPERATION MOVE BLACK WIRE FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER 3 CRANKCAS...

Page 69: ... 3 BK BK 1 C 24V BL 2 TR 3 240 3 4 2 1 RD VMR BK PU PU BL PU YL 208 NOTE 2 SEE NOTE 6 RD BK BK OPTIONAL LOW VOLTAGE OPTIONAL HIGH VOLTAGE FIELD INSTALLED CONTROL FIELD INSTALLED POWER NOTES 1 REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE OF INSULATION AS ORIGINAL USE COPPER CONDUCTOR ONLY 2 FOR 208 VOLT TRANSFORMER OPERATION MOVE BLACK WIRE FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER 3 CRANKCAS...

Page 70: ...D RD RD PU WH OR RD PLF YL YL YL GR PU YL Y Y2 Y1 1 2 3 IGN FS RCCF PU BL BR PU RD RD YL YL RS PU PU BL VM PU L2 UNUSED HEAT FS L1 DI 1 3 6 5 2 4 10 7 9 12 8 11 150 120 ECON 135 P1 F1 FUSE 3 AMP MAX P3 GR RD YL WH YL YL COMPRESSOR COOL SCREW REQUIRED P2 T1 MOUNT C22 T2 BREAK FOR TWO STAGE SPEED UP GR WH WHGR BL RD C RD TO THERMOSTAT ALS PS GV MV ALT HONEYWELL GAS VALVE GV MV GAS VALVE W R YL SEE N...

Page 71: ...TION MOVE BLACK WIRE FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER 3 CRANKCASE HEATER NOT SUPPLIED ON ALL UNITS 4 FOR DIFFERENT THAN FACTORY SPEED TAP CHANGE COOLING SPEED AT MOTOR T4 AND T5 TERMINALS CHANGE HEATING SPEED AT MOTOR T1 T2 AND T3 TERMINALS COOLING SPEED YELLOW WIRE HEATING SPEED WHITE WIRE T4 LOW SPEED T1 LOW SPEED T5 HIGH SPEED T2 MED SPEED T3 HIGH SPEED 5 ACCESSORY ECONOMIZER PLUG A...

Page 72: ...W INDUCER L2 BK RD GR SEE NOTE 3 EM 208 PU YL PU BK N G L T5 T4 T3 T2 T1 240 3 TR 2 RD 24V C 1 YL BL 208 230 3 60 POWER SUPPLY GND C PU PU RD BK BR PU BK T2 T3 COMP T1 T2 T1 CC L2 L1 ALS CM LPS HPS SOL PARK BK PU ODF OUTDOOR FAN HPS LPS SEE NOTE 3 1 2 3 SEE NOTE 2 BL BK SEE NOTE 7 HIGH PRESSURE SWITCH HPS LPS LOW PRESSURE SWITCH SEE NOTE 2 YL YL YL YL YL YL YL YL YL PU F WH BR YL BL OR OR YL PU BR...

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