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: Service Manual

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

18

2. Temperature of windings must be as specified, usually about 70_F

(21.1ºC) .

3. Resistance measuring instrument must have an accuracy within ±

5-10  percent.  This  requires  an  accurate  ohmmeter  such  as  a

Wheatstone bridge or null balance-type instrument. 

4. Motor  must  be  dry  or  free  from  direct  contact  with  liquid

refrigerant. 

Make This Critical Test

(Not advisable unless above conditions are met.)

1. Be sure all power is off.
2. Discharge all capacitors. 
3. Remove wires from terminals C, S, and R. 
4. Place instrument probes together and determine probe and lead wire

resistance. 

5. Check resistance readings from C-R, C-S, and R-S. 
6. Subtract instrument probe and lead resistance from each reading. 

If  any  reading  is  within    ±20  percent  of  known  resistance,  motor  is

probably normal. Usually a considerable difference in reading is noted if

a turn-to-turn short is present. 

System Clean-Up After Burnout 

Turn off  all power to  unit before proceeding. Wear safety glasses and

gloves  when  handling  refrigerants. Acids  formed  as  a  result  of  motor

burnout can cause burns. 

NOTE: 

To analyze level of suspected contamination from compressor

burnout, use Total Test™. See your distributor/branch.
Some compressor electrical failures can cause motor to overheat. When

this  occurs,  byproducts,  which  include  sludge,  carbon,  and  acids,

contaminate  system.  If  burnout  is  severe  enough,  system  must  be

cleaned  before  replacement  compressor  is  installed.  The  2  types  of

motor burnout are classified as mild or severe.
In mild burnout, there is little or no detectable odor. Compressor oil is

clear  or  slightly  discolored.  An  acid  test  of  compressor  oil  will  be

negative. This type of failure is treated the same as mechanical failure.

Liquid  line  strainer  should  be  removed  and  liquid  line  filter  drier

installed.
In  a  severe  burnout,  there  is  a  strong,  pungent,  rotten  egg  odor.

Compressor  oil  is  very  dark.  Evidence  of  burning  may  be  present  in

tubing connected to compressor. An acid test of compressor oil will be

positive.  Complete  system  must  be  reverse  flushed  with  refrigerant.

Metering  device  must  be  cleaned  or  replaced.  In  a  heat  pump,

accumulator  and  reversing  valve  are  replaced.  These  components  are

also removed and bypassed during reverse flushing procedure. Remove

and  discard  liquid  line  strainer.  After  system  is  reassembled,  install

liquid and suction line filter driers. Run system for 2 hrs. Discard both

driers and install new liquid line drier only.

Compressor Removal and Replacement 

Once  it  is  determined  that  compressor  has  failed  and  the  reason

established, compressor must be replaced. 

1. Shut off all power to unit. 
2. Remove  and  recover  all  refrigerant  from  system  until  pressure

gages read zero psig. Use all service ports.

3. Disconnect electrical plug from compressor. Disconnect or remove

crankcase heater (if equipped) and  remove compressor holddown

nuts and washers. 

4. Cut  compressor  from  system  with  tubing  cutters.  Do  not  use

brazing torch for compressor removal. Oil vapor may ignite when

compressor is disconnected.

5. Scratch  matching  marks  on  stubs  in  old  compressor.  Make

corresponding marks on replacement compressor. 

6. Use  torch  to  remove  stubs  from  old  compressor  and  to  reinstall

them in replacement compressor. 

7. Use copper couplings to tie compressor back into system. 
8. Evacuate system, recharge, and check for normal system operation. 
9. Compressors  have  copper  plated  steel  suction  ports.  Excess  heat

during brazing will burn off copper plating. See Brazing section for

additional information.

Outdoor Fan Adjustment

1. Shut off unit power supply and install lockout tag.
2. Remove outdoor-fan assembly (grille, motor, motor cover, and fan)

by removing screws and flipping assembly onto unit top cover.

3. Inspect the fan blades for cracks or bends.
4. If fan needs to be removed, loosen the setscrew and slide the fan off

the motor shaft.

5. When  replacing  fan  blade,  position  blade  as  shown  in 

Fig. 19

.

Tighten setscrews.

Fan Motor

The fan motor rotates the fan blade that draws air through the outdoor

coil  to  exchange  heat  between  the  refrigerant  and  the  air.  Motors  are

totally enclosed to increase reliability. This eliminates the need for a rain

shield. For the correct position of fan blade assembly, the fan hub should

be flush with the motor shaft. Replacement motors and blades may vary

slightly.

WARNING

!

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:

The high flow service valve is equipped with Schrader valves.

WARNING

!

PERSONAL INJURY AND ENVIRONMENTAL HAZARD

Failure to follow this warning could result in personal injury or death.

Relieve  pressure  and  recover  all  refrigerant  before  system  repair  or

final  unit  disposal.  Use  all  service  ports  and  open  all  flow-control

devices, including solenoid valves. Federal regulations require that you

do not vent refrigerant to the atmosphere. Recover during system repair

or final unit disposal.

CAUTION

!

UNIT OPERATION HAZARD

Failure to follow this caution may result in damage to unit components.
Keep  the  condenser  fan  free  from  all  obstructions  to  ensure  proper

cooling operation. Never place articles on top of unit.

Содержание 024-036

Страница 1: ...ns Rotating fan blades can cause personal injury Appropriate safety considerations are posted throughout this manual where potentially dangerous techniques are addressed Follow all safety codes Wear safety glasses protective clothing and work gloves Have a fire extinguisher available Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the u...

Страница 2: ... low ambient cooling applications Suggested in all commercial applications 2 Evaporator Freeze Thermostat An SPST temperature actuated switch that stops unit operation when evaporator reaches freeze up conditions Usage Guideline Required when low ambient kit has been added 3 Isolation Relay An SPDT relay which switches the low ambient controller out of the outdoor fan motor circuit when the heat p...

Страница 3: ...ls must meet the original equipment specifications Insulation must meet NFPA 90A requirements for flame spread and smoke generation Foam gaskets that are in the conditioned air stream must meet the requirements of UL 94 5VA for flammability Instructions for insulation installation 1 Apply adhesive on non foil side of the insulation 2 Align insulation to the panel 3 Care must be taken while applyin...

Страница 4: ... reserves the right to change at any time specifications and designs without notice and without obligations 4 A220851 Fig 3 Unit Base Dimensions Small Medium Cabinet with Full Louver 13 4 SEER2 HEAT PUMP 13 4 SEER2 AIR CONDITIONER ...

Страница 5: ... the right to change at any time specifications and designs without notice and without obligations 5 A220853 Fig 4 Unit Base Dimensions Heat Pump Air Conditioner Large Cabinet with Full Slots 13 4 SEER2 HEAT PUMP 13 4 SEER2 AIR CONDITIONER ...

Страница 6: ...acturer reserves the right to change at any time specifications and designs without notice and without obligations 6 A220854 Fig 5 13 4 SEER2 Air Conditioner Medium and Large Cabinet with Louvers 13 4 SEER2 Air Conditioner ...

Страница 7: ... panel to access components above See Fig 7 3 Access or removal of the condenser coil a Removal of the top the control compressor panel the front left side louver panel b Screws from the compressor compartment and either the side of the unit or below the condenser fan depending on the shape of coil will need to be removed to remove condenser coil See Fig 8 4 Access or removal of the evaporator coi...

Страница 8: ...ons 8 Labeling The wiring schematic sub cooling charging tables with instructions and warning labels Refer to Fig 10 for label location A10163 Fig 10 Label Location FIELD CONNECTIONS BLOWER PANEL WIRING DIAGRAM ON BACKSIDE OF CONTROL FRONT OF CONTROL COMPRESSOR PANEL WARNING ADVERTISSMENT WARNING ADVERTISSMENT WARNING ADVERTISSMENT ...

Страница 9: ...0k scale Using an analog ohmmeter check each terminal to ground use capacitor case Discard any capacitor which measures 1 2 scale deflection or less Place ohmmeter leads across capacitor and place on R X 10k scale Meter should jump to a low resistance value and slowly climb to higher value Failure of meter to do this indicates an open capacitor If resistance stays at 0 or a low value capacitor is ...

Страница 10: ...s or heat pumps R 410A pressure switches are identified by a pink stripe down each wire Low Pressure Switch Neither of the air conditioner or heat pump units have a low pressure switch The heat pump models have a loss of charge switch located downstream of the liquid line filter drier See loss of charge for more details High Pressure Switch AC HP The high pressure switch is located in the discharg...

Страница 11: ...at or Off the valve is de energized There is no compressor delay built into this control A05332 Fig 14 Defrost Control Heating Sequence of Operation On a call for heating thermostat makes R Y and R G Circuit R Y sends low voltage through the safeties and energizes the contactor which starts the compressor and energizes the T1 terminal on the circuit board The T1 terminal energizes the defrost logi...

Страница 12: ...gations 12 A220832 Fig 15 DFT Sensor Location 024 048 SEE DETAIL B DETAIL SEE DETAIL D DETAIL D SEE DETAIL F DETAIL SEE DETAIL H DETAIL H HIURVW WKHUPRVWDW FDQ HLWKHU EH ORFDWHG RQ WKH ERWWRP RI WXEH DV VKRZQ RU RQ WKH WRS DQG PXVW QRW LQWHUIHUH ZLWK DQ RWKHU WXELQJ 030 036 13 4 SEER2 042 13 4 SEER2 048 13 4 SEER2 024 13 4 SEER2 ...

Страница 13: ...Whether the unit is in heating or cooling mode it will run a defrost cycle for 10 minutes each time the compressor has been energized for the selected time interval The board will terminate automatically after 10 minutes of defrost time regardless of defrost thermostat position If defrost thermostat is stuck open The unit will not defrost If unit will not defrost 1 Perform the speedup function as ...

Страница 14: ...0 F 10ºC to 70 F 21 1ºC Resistance goes from zero to when contacts are open 8 If either opening or closing temperature does not fall within above ranges or thermostat sticks in 1 position replace thermostat to ensure proper defrost operation NOTE With timing cycle set at 90 minutes unit initiates defrost within approximately 21 sec When you hear the reversing valve changing position remove screwdr...

Страница 15: ... manufacturer s performance data 4 A whistling or squealing noise during operation may indicate a partial blockage of the refrigerant charge 5 A whistle on shut down could indicate a partial leak path as refrigerant is equalizing from high to low side On occasion an in line discharge check valve has prevented this sound 6 If a compressor hums but won t start it could indicate either a voltage or a...

Страница 16: ... sources of problems have been eliminated compressor must be replaced Because compressor is a sealed unit it is impossible to determine exact mechanical failure However complete system should be checked for abnormalities such as incorrect refrigerant charge restrictions insufficient airflow across indoor or outdoor coil etc which could be contributing to the failure Runs Does Not Pump In this type...

Страница 17: ...not run although external electrical and mechanical systems appear normal Compressor must be checked electrically for abnormalities Before troubleshooting compressor motor review this description of compressor motor terminal identification Single Phase Motors To identify terminals C S and R 1 Turn off all unit power 2 Short the run and start capacitors to prevent shock 3 Remove all wires from moto...

Страница 18: ...mpressor Removal and Replacement Once it is determined that compressor has failed and the reason established compressor must be replaced 1 Shut off all power to unit 2 Remove and recover all refrigerant from system until pressure gages read zero psig Use all service ports 3 Disconnect electrical plug from compressor Disconnect or remove crankcase heater if equipped and remove compressor holddown n...

Страница 19: ...ing or first stage heating for heat pumps O Energizes reversing valve on heat pumps C Common side of transformer G Indoor Fan Ground Circuit To determine if a wire has broken or come in direct contact with shell causing a direct short to ground follow these steps 1 Recover all refrigerant charge 2 Using an ohmmeter on R X 10 000 ohm scale or megohmmeter follow manufacturer s instructions 3 Be sure...

Страница 20: ...checked such as frost or condensate water on refrigerant tubes The sound made by a reversing valve as it begins or ends defrost is a whooshing sound as the valve reverses and pressures in system equalize An experienced service technician detects this sound and uses it as a valuable troubleshooting tool Using a remote measuring device check inlet and outlet line temperatures DO NOT touch lines If r...

Страница 21: ...tor with liquid refrigerant The bleed hole allows a small amount of oil and refrigerant to enter the return line where velocity of refrigerant returns it to compressor If bleed hole plugs oil is trapped in accumulator and compressor will eventually fail from lack of Table 3 Compressor Information 13 4 SEER2 AC Unit Size 24 30 36 42 48 60 Type Emerson Scroll Emerson Scroll Emerson Scroll LG Scroll ...

Страница 22: ...tdown TXVs are specifically designed to operate with R 410A refrigerant use only factory authorized TXV s Do not interchange R 410A and R 22 TXVs TXV Operation The TXV is a metering device that is used in air conditioning and heat pump systems to adjust to changing load conditions by maintaining a preset superheat temperature at the outlet of the evaporator coil The volume of refrigerant metered t...

Страница 23: ...ston TXV Number Outdoor Heating Piston Number 13 4 SEER2 24 57 30 63 36 67 42 76 48 80 60 TXV Heat Pump Unit Size ton Indoor Cooling Piston TXV Number Outdoor Heating Piston Number 13 4 SEER2 24 57 30 63 55 36 67 57 42 76 59 48 TXV 60 TXV 70 WARNING PERSONAL INJURYAND ENVIRONMENTAL HAZARD Failure to relieve system pressure could result in personal injury and or death 1 Relieve pressure and recover...

Страница 24: ...power to unit 2 Recover refrigerant from system through high flow service valves 3 Break vacuum with nitrogen 4 Remove top cover See Access Compressor or other internal cabinet component Fig 6 Fig 8 5 Remove screws in coil panels 6 Use midget tubing cutter to cut liquid and vapor lines at both sides of coil Cut in convenient location for easy reassembly with copper slip couplings 7 Lift coil verti...

Страница 25: ...and assure a tight dry system before charging The 2 methods used to evacuate a system are the deep vacuum method and the triple evacuation method Deep Vacuum Method The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gauge capable of accurately measuring this vacuum depth The deep vacuum method is the most positive way of assuring a system is free ...

Страница 26: ...ely not controlling properly i e stuck open REPLACE VALVE If superheat is higher than 15 F proceed to Step 3 3 Perform TXV function check With system running place sensing bulb in ice bath for 1 minute superheat should increase If no response Replace Valve If OK proceed to Step 4 4 Check for even temperature distribution at outlet of each circuit of evaporator If greater than 15 F between circuits...

Страница 27: ...air return air wet bulb temperature with a sling psychrometer or electronic equivalent 6 Using Superheat Charging Table Table 6 find outdoor temperature and indoor air wet bulb temperature At this intersection note superheat Where a dash appears on table do not attempt to charge unit under these conditions or refrigerant slugging may occur In this situation refrigerant must be evacuated and weighe...

Страница 28: ... for Safe Electric Heater Operation Air Conditioner AC Unit Size Minimum Airflow CFM 5 kW 7 5 kW 10 kW 15 kW 20 kW 24 600 750 750 X X 30 600 750 750 X X 36 600 750 750 1050 X 42 600 750 750 1050 X 48 600 750 750 1050 1400 60 600 750 750 1050 1400 Heat Pump HP Unit Size Minimum Airflow CFM 5 kW 7 5 kW 10 kW 15 kW 20 kW 24 750 800 800 X X 30 750 800 800 X X 36 750 800 800 1200 X 42 750 800 800 1200 ...

Страница 29: ...12 107 102 97 92 2785 45 42 39 36 33 414 114 109 104 99 94 2854 46 43 40 37 34 424 116 111 106 101 96 2923 47 44 41 38 35 434 118 113 108 103 98 2992 48 45 42 39 36 444 119 114 109 104 99 3061 48 46 43 40 37 454 121 116 111 106 101 3130 49 47 44 41 38 464 123 118 113 108 103 3199 50 48 45 42 39 474 124 119 114 109 104 3268 51 48 46 43 40 484 126 121 116 111 106 3337 52 49 47 44 41 494 127 122 117 ...

Страница 30: ...ower off to the unit Disconnect the two plugs going into the motor One plug is the high voltage supply and the other is the low voltage control Cycle power back on and measure the high voltage supply plug to determine if there is voltage at plug If there is no voltage at plug determine if there is power to the unit The easiest place to measure the voltage is on the line side of the contactor If th...

Страница 31: ...ntrol panel will expose most of the unit s components Both the air conditioner and heat pump control boxes will be in the upper right corner of the unit There will be a contactor that cycles components off and on The capacitor will assist the outdoor fan and compressor to operate The heat pump models will have a circuit board to control the defrost cycle Always replace these devices with the Facto...

Страница 32: ...lectric Heat wiring interconnection electric heater controls removed for clarity Electric Heat Control Box shown uninstalled Electric Heat wiring interconnection electric heater controls removed for clarity Electric Heat Control Box shown uninstalled Air Conditioning Control Box Wiring Heat Pump Control Box Wiring A10030 A10031 HIGH VOLTAGE POWER WIRING ENTRY HOLE LOW VOLTAGE WIRING ENTRY HOLE gro...

Страница 33: ...ual Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 33 A210120 Fig 33 Typical Air Conditioning Single Phase Unit Connection Electrical Diagram ...

Страница 34: ...anual Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 34 A210121 Fig 34 Typical Air Conditioning Single Phase Unit Ladder Electrical Diagram ...

Страница 35: ...ervice Manual Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 35 A210797 Fig 35 Typical Heat Pump Unit Connection Electrical Diagram ...

Страница 36: ... Service Manual Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 36 A210799 Fig 36 Typical Heat Pump Unit Ladder Electrical Diagram ...

Страница 37: ...d basepan 5 Reinstall side panel 6 Reconnect electrical power and check for proper operation Cleaning Outdoor Fan Motor and Blade 1 Remove grille fan motor and blade Be careful not to bend or dent fan blade 2 Clean motor and blade with soft brush or cloth Be careful not to disturb balance weights on fan blade 3 Check fan blade setscrew for tightness 4 Reinstall fan motor and blade to grille and ch...

Страница 38: ...3 53 5 592 147 9 64 4 58 7 3 13 7 160 56 2 13 4 262 86 9 30 5 364 110 0 43 3 466 128 7 53 7 596 148 4 64 7 60 8 6 13 0 162 57 0 13 9 264 87 4 30 8 366 110 4 43 6 468 129 0 53 9 600 149 0 65 0 62 10 0 12 2 164 57 7 14 3 266 87 9 31 1 368 110 8 43 8 470 129 3 54 1 604 149 5 65 3 64 11 3 11 5 166 58 4 14 7 268 88 4 31 3 370 111 2 44 0 472 129 7 53 2 608 150 1 65 6 66 12 6 10 8 168 59 0 15 0 270 88 9 ...

Страница 39: ...TIVE RUN CAPACITOR OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT LOOSE LEAD AT FAN MOTOR MOTOR DEFECTIVE LOW SUCTION PRESSURE DIRTY AIR FILTERS DUCT RESTRICTED DAMPERS PARTLY CLOSED COM...

Страница 40: ...OAD CONDITION REVERSING VALVE JAMMED IN MIDPOSITION HIGH SUPERHEAT DEFECTIVE FAN MOTOR CAPACITOR LOOSE LEADS AT FAN MOTOR FAN MOTOR BURNED OUT LOW SUCTION LOW HEAD OUTDOOR FAN STOPPED LOOSE LEADS AT OUTDOOR FAN MOTOR INTERNAL FAN MOTOR KLIXON OPEN FAN MOTOR BURNED OUT DEFROST RELAY N C CONTACTS OPEN ON CIRCUIT BOARD REVERSING VALVE DID NOT SHIFT UNIT NOT PROPERLY CHARGED OUTDOOR FAN RUNNING REVERS...

Страница 41: ...R OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING DAMAGED OR STUCK REVERSING VALVE RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT LOOSE LEAD AT FAN MOTOR DEFROST RELAY N C CONTACTS OPEN MOTOR DEFECTIVE LOW SUCTION PRESSURE DIRTY AIR F...

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