Daikin DCH090, DCC060, DCH060, DCH072, DCH102 Service Instructions Manual

...

Ser vice Instr uctions

DCC Cooling/DCH Heat Pumps

Commercial Package Units

with R-410A Refrigerant

4 - 6 Tons & Accessories

Not for installation in the United S tates or Canada. This unit is for export only.

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.

RSDX6412006r1

November 2016

T ABLE OF CONTENTS

IMPORTANT INFORMATION .................................2 - 3

PRODUCTION IDENTIFICATION ..........................4 - 6

PRODUCT DESIGN .............................................7 - 10

SYSTEM OPERATION.......................................11 - 16

SCHEDULED MAINTENANCE ................................. 17

TROUBLESHOOTING CHARTS ................................ 18

SERVICING TABLE OF CONTENTS ........................ 19

SERVICING .......................................................20 - 39

UNIT WIRING DIAGRAMS ....................................... 40

IMPORTANT INFORMATION

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE

APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

NLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL ADJUST, SERVICE OR REPAIR (HEREINAFTER EQUIPMENT SPECIFIED IN THIS MANUAL SHOULD SERVICE THE EQUIPMENT FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY INJURY OR PROPERTY DAMAGE WHICH MAY RESULT JURISDICTIONS THAT REQUIRE ONE OR MORE LICENSES TO SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL, ONLY LICENSED PERSONNEL SHOULD SERVICE THE EQUIPMENT

MPROPER INSTALLATION, ADJUSTMENT, SERVICING OR REPAIR

OF THE EQUIPMENT SPECIFIED IN THIS MANUAL, OR ATTEMPTING TO INSTALL, ADJUST, SERVICE OR REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER TRAINING MAY RESULT IN PRODUCT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

. THE

MANUFACTURER WILL NOT BE RESPONSIBLE

, “

. IN

ADDITION, IN

SERVICE

. IF

”)

THE

YOU SERVICE

Do not store combustible materials or use gasoline or other flammable liquids or vapors in the vicinity of this appliance as property damage or personal injury could occur. Have your contractor point out and identify the various cut-off devices, switches, etc., that serves your comfort equipment.

HIGH VOLTAGE! Disconnect ALL power before servicing or installing this unit. Multiple power sources may be present. Failure to do so may cause prop er t y dam a ge, pe r sonal injury or de a t h.

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

CONSUMER INFORMATION LINE - DAIKIN BRAND PRODUCTS

TOLL FREE 1-855-770-5678 (U.S. only)

email us at: customerservice@daikincomfort.com

fax us at: (713) 856-1821

(Not a technical assistance line for dealers.)

Outside the U.S., call 1-713-861-2500

(Not a technical assistance line for dealers.)

Your telephone company will bill you for the call.

IMPORTANT INFORMATION

SAFE REFRIGERANT HANDLING

While these items will not cover every conceivable situation, they should serve as a useful guide.

Refrigerants are heavier than air. They can "push out" the oxygen in your lungs or in any enclosed space.To avoid possible difficulty in breathing or death:

•

Never purge refrigerant into an enclosed room or

space. By law, all refrigerants must be reclaimed.

•

If an indoor leak is suspected, thoroughly ventilate

the area before beginning work.

• Liquid refrigerant can be very cold. To avoid possible frostbite or blindness, avoid contact with refrigerant and wea r gloves and gog gles. If liquid r efrige rant does cont act your sk in or eyes, seek medic al help immediately.

WARNING

To avoid possible injury, explosion or death, practice safe handling of refrigerants.

The compre ssor POE oil for R-410A units is extremely susceptible to moisture absorption and could cause compressor failu r e. Do not leave system open to atmosphere any longer than necessary for insta llat i o n .

To avoid possible e xplosio n, use only returnabl e (n ot disposable) service cylinders when removing refrigerant from a system.

• Ensure the cylinde r is f ree of damage which could lead to a leak or explosio n .

• Ensure the hydrostatic test date does not exceed 5 years.

• Ensure the pressure rating meets or exceeds 400 lbs. When in doubt, do not use cylinder.

WARNING

System contamina nts, improper se rvice procedure and/or physical abuse affecting hermetic com pressor electrical terminals may cause dangerous s ystem venting.

The successful development of hermetically sealed refrigeration compressors has completely sealed the compressor's moving parts and electric motor inside a common housing, minimizing refrigerant leaks and the hazards sometimes associated with moving belts, pulleys or couplings.

Fundamental to the design of hermetic compressors is a method whereby electrical current is transmitted to the compressor motor through terminal conductors which pass through the compressor housing wall. These terminals are sealed in a dielectric material which insulates them from the housing and maintains the pressure tight integrity of the hermetic compressor. The terminals and their dielectric embedment are strongly constructed, but are vulnerable to careless compressor installation or maintenance procedures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants.

In either of these instances, an electrical short between the terminal and the compressor housing may result in the loss of integrity between the terminal and its dielectric embedment. This loss may cause the terminals to be expelled, thereby venting the vaporous and liquid contents of the compressor housing and system.

A venting compressor terminal normally presents no danger to anyone, providing the terminal protective cover is properly in place.

If, however, the terminal protective cover is not properly in place, a venting terminal may discharge a combination of

(a ) hot lubricating oil and refrigerant (b ) flammable mixture (if system is contaminated

with air)

in a stream of spray which may be dangerous to anyone in the vicinity. Death or serious bodily injury could occur.

Under no circumstances is a hermetic compressor to be electrically energized and/or operated without having the terminal protective cover properly in place.

See Service Section S-17 for proper servicing.

PRODUCT IDENTIFICA TION

The model number is used for positive identification of component parts used in manufacturing. Please use this number when requesting service or parts information.

DCC090045 5 D***

1 2 3 4, 5, 6 7, 8, 9 10 11 12 13 14

Brand

DDaikin

Configuration

C Standard Efficiency XNo Options

Application

C Cooling X Standard Aluminized Heat Exchange HHeat Pump S Stainle ss Steel Gas Heat Exchanger

Nominal Gross Cooling Capacit

036 3 Tons 102 8½ Ton s 048 4 Tons 120 10 Tons 060 5 Tons 180 15 Tons 072 6 Tons 240 20 Tons BBelt Drive 090 7½ T on s D Direct Dr ive

Nominal Heating Capacit

Gas/Electric A/C H/P Factory-Installed Electric Heat

180 180,000 BTU/h X XX No Heat 030 30 kW 1 208-230/1/60 ( Unit ed St ates) 4 460/ 3/60 (United Stat es) 300 300,00 0 BTU/h 016 15 kW 045 44 kW 3 208-230/3/60 (Un ited States) 5 400/3/50 (Russia Daikin B rand) 350 350,00 0 BTU/h 6 400/3/ 60 ( Saudi Ar ab ia) A 400/3 /50 (Russia Goodman Bran d)

B 400/3/50 (Kuwait) E 400/3/50 (Argentina)

See product specifications for heat size(s) available for each c apacit y.

A *

15 16

Revision Levels

Major & Minor

Factory-Install ed Optio ns

XNo Options

Supply Fan/Drive Type/Motors

Voltage

PRODUCT IDENTIFICA TION

Daikin Commer cial Multiposition Package Heat Pumps

Models Description

DCH[048-060]XXX6DXXXAA

DCH072XX X6BX XXAA DCH048XXX6 DXXXAD

DCH060XXX6 DXXXAC DCH072XX X6BX XXAC

Daikin Commercial Package Heat Pump, Multiposition heat pump units, 400V 3 Phase, 60 Hz Di rect Dr ive. Initial release of Daikin branded models.

Daikin Commercial Package Heat Pump, Multiposition heat pump units, 400V 3 Phase, 60 Hz Di rect Drive with Phase Monitor.

DCH***XXX**XXX

These units have R410A refrigerant

PRODUCT IDENTIFICA TION

Daikin Co mmercia l M ultip o s it io n Pa c k a g e C oo le rs

Models Description

DCC[048-060]XXX6DXXXAA

DCC072XXX6BXXXAA

DCC[048-060]XXXBDXXXAA

DCC[048-060]XXX6DXXXAC Daikin Commercial Package Cooler, Multiposition cooling, 400V 3 Phase, 50 Hz Direct Drive with Phase Monitor.

DCC072XXX6BXXXAC Daikin Commercial Package Cooler, Multiposition cooling, 400V 3 Phase, 50 Hz Direct Drive with Phase Monitor.

Daikin Commercial Package Cooler, Multiposition cooling, 400V 3 Phase, 60 Hz Direct Drive. Initial release of 4-5 Ton Daikin branded models.

Daikin Commercial Package Cooler, Multiposition cooling, 400V 3 Phase, 60 Hz Direct Drive. Initial release of Daikin branded models with SASO level 2 regulations.

DCC***XXX**XXX

These units have R410A refrigerant

PRODUCT DESIGN

UNIT LOCATION

WARNING

O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET P OINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

IMPORTANT NOTE: Remove wood shipping rails prior to

installation of the unit.

ALL INSTALLATIONS:

NOTE: Appliance is shipped from factory for vertical duct

application. Proper installation of the unit ensures trouble-free operation. Improper installation can result in problems ranging from noisy operation to property or equipment damages, dangerous conditions that could result in injury or personal property damage. Give this booklet to the user and explain it’s provisions. The user should retain these instructions for future reference.

• For proper flame pattern within the heat exchanger and

proper condensate drainage, the unit must be mounted level.

• The flue outlet must be at least 12 inches from any

opening through which flue gases could enter a building, and at least three feet above any forced air inlet located within ten feet. The economizer/manual fresh air intake/ motorized fresh air intake and combustion air inlet mounted on the unit are not affected by this restriction.

• To avoid possible corrosion of the heat exchanger, do not

locate the unit in an area where the outdoor air (i.e. combustion air for the unit) will be frequently contaminated by compounds containing chlorine or fluorine. Common sources of such compounds include swimming pool chemicals and chlorine bleaches, paint stripper, adhesives, paints, varnishes, sealers, waxes (which are not yet dried) and solvents used during construction and remodeling. Various commercial and industrial processes may also be sources of chlorine/fluorine compounds.

• To avoid possible illness or death of the building occu-

pants, do NOT locate outside air intake device (economizer, manual fresh air intake, motorized fresh air intake) too close to an exhaust outlet, gas vent termination, or plumbing vent outlet. For specific distances required, consult local codes.

• Allow minimum clearances from the enclosure for fire

protection, proper operation, and service access (see unit clearances). These clearances must be permanently maintained.

• The combustion air inlet and flue outlet on the unit must

never be obstructed. If used, do not allow the economizer/manual fresh air damper/ motorized fresh air damper to become blocked by snow or debris. In some climates or locations, it may be necessary to elevate the unit to avoid these problems.

• When the unit is heating, the temperature of the return air

entering the unit must be a minimum of 55° F.

GROUND LEVEL INSTALLATIONS ONLY:

• When the unit is installed on the ground adjacent to the

building, a level concrete (or equal) base is recommended. Prepare a base that is 3” larger than the package unit footprint and a minimum of 3” thick.

• The base should also be located where no runoff of water

from higher ground can collect in the unit.

ROOF TOP INSTALLATIONS ONLY:

• To avoid possible property damage or personal injury, the

roof must have sufficient structural strength to carry the weight of the unit(s) and snow or water loads as required by local codes. Consult a structural engineer to determine the weight capabilities of the roof.

• The unit may be installed directly on wood floors or on

Class A, Class B, or Class C roof covering material.

• To avoid possible personal injury, a safe, flat surface for

service personnel should be provided.

• As indicated on the unit data plate, a minimum clearance

of 36” to any combustible material is required on the furnace access side of the unit. All combustible materials must be kept out of this area.

• This 36” clearance must also be maintained to insure

proper combustion air and flue gas flow. The combustion air intake and furnace flue discharge must not be blocked for any reason, including blockage by snow.

• Adequate clearances from the furnace flue discharge to

any adjacent public walkways, adjacent buildings, building openings or openable windows must be maintained in accordance with the latest edition of the National Fuel Gas Code (ANSI Z223.1)

• Minimum horizontal clearance of 48” from the furnace flue

discharge to any electric meters, gas meters, regulators and relief equipment is required.

UNIT PRECAUTIONS

• Do not stand or walk on the unit.

• Do not drill holes anywhere in panels or in the base frame of the unit except where indicated. Unit access panels provide structural support.

• Do not remove any access panels until unit has been installed on roof curb or field supplied structure.

• Do not roll unit across finished roof without prior approval of owner or architect.

• Do not skid or slide on any surface as this may damage unit base. The unit must be stored on a flat, level surface. Protect the condenser coil because it is easily damaged.

PRODUCT DESIGN

ROOF CURB INSTALLATIONS ONLY:

Curb installations must comply with local codes and should be done in accordance with the established guidelines of the National Roofing Contractors Association.

Proper unit installation requires that the roof curb be firmly and permanently attached to the roof structure. Check for adequate fastening method prior to setting the unit on the curb.

Full perimeter roof curbs are available from the factory and are shipped unassembled. Field assembly, squaring, leveling and mounting on the roof structure are the responsibility of the installing contractor. All required hardware necessary for the assembly of the sheet metal curb is included in the curb accessory.

WARNING

O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

• Sufficient structural support must be determined prior to

locating and mounting the curb and package unit.

• Ductwork must be constructed using industry guide-

lines. The duct work must be placed into the roof curb before mounting the package unit. Our full perimeter curbs include duct connection frames to be assembled with the curb. Cantilevered type curbs are not available from the factory.

• Curb insulation, cant strips, flashing and general roofing

material are furnished by the contractor. The curbs must be supported on parallel sides by roof members. The roof members must not penetrate supply and return duct opening areas as damage to the unit might occur.

CLEARANCES

24”

Min.*

36” Min.

24”

Min.*

Unit Clearances

*In situations that have multiple units, a 48” minimum clearance is required between the condenser coils.

Adequate clearance around the unit should be kept for safety, service, maintenance, and proper unit operation. A total clearance of 75” on the main control panel side of the unit is recommended to facilitate possible fan shaft, coil, electric heat and gas furnace removal. A clearance of 48” is recommended on all other sides of the unit to facilitate possible compressor removal, to allow service access and to insure proper ventilation and condenser airflow. The unit must not be installed beneath any obstruction. The unit should be installed remote from all building exhausts to inhibit ingestion of exhaust air into the unit fresh air intake.

NOTE: The unit and curb accessories are designed to allow vertical duct installation before unit placement. Duct installation after unit placement is not recommended.

CAUTION

ALL

CURBS LOOK SIMILAR POSITIONING, CHECK JOB PLANS CAREFULLY AND VERIFY MARKINGS ON CURB ASSEMBLY SUPERSEDES INFORMATION SHOWN

. TO

AVOID INCORRECT CURB

. I

NSTRUCTIONS MAY VARY IN CURB STYLES AND

See the manual shipped with the roof curb for assembly and installation instructions.

PROTRUSION

Inspect curb to ensure that none of the utility services (electric) routed through the curb protrude above the curb.

ELECTRICAL WIRING

HIGH VOLTAGE! D

ISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT BE PRESENT DAMAGE, PERSONAL INJURY OR DEATH

. F

. M

AILURE TO DO SO MAY CAUSE PROPERTY

W ARNING

ULTIPLE POWER SOURCES MAY

PRODUCT DESIGN

WARNING

HIGH VOLTAGE!

O AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DO NOT TAMPER WITH FACTORY WIRING

. THE

OF THESE UNITS ARE FACTORY-INSTALLED AND HAVE BEEN THOROUGHLY TESTED PRIOR TO SHIPMENT

ONTACT YOUR LOCAL REPRESENTATIVE IF

ASSISTANCE IS REQUIRED

INTERNAL POWER AND CONTROL WIRING

CAUTION

PREVENT DAMAGE TO THE WIRING, PROTECT WIRING FROM SHARP EDGES LOCAL CODES AND ORDINANCES REMOVABLE ACCESS PANELS

. F

OLLOW NATIONAL ELECTRICAL CODE AND ALL

. DO

NOT ROUTE WIRES THROUGH

CAUTION

ONDUIT AND FITTINGS MUST BE WEATHER-TIGHT TO PREVENT

WATER ENTRY INTO THE BUILDING

For unit protection, use a fuse or HACR circuit breaker that is in excess of the circuit ampacity, but less than or equal to the maximum overcurrent protection device. DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN ON UNIT DATA PLATE.

All line voltage connections must be made through weatherproof fittings. All exterior power supply and ground wiring must be in approved weatherproof conduit.

The main power supply wiring to the unit and low voltage wiring to accessory controls must be done in accordance with these instructions, the latest edition of the National Electrical Code (ANSI/NFPA 70), and all local codes and ordinances. All field wiring shall conform with the temperature limitations for Type T wire (63°F/35°C rise).

The unit is factory wired for the voltage shown on the unit’s data plate. Refer to model nomenclature in Appendix B for voltage requirement for your unit.

NOTE: If supply voltage is 208V, lead on primary of transformer must be moved from the 230V to the 208V tap. Refer to wiring diagram on unit for details.

Main power wiring should be sized for the minimum wire ampacity shown on the unit’s database. Size wires in accordance with the ampacity tables in Article 310 of the National Electrical Code. If long wires are required, it may be necessary to increase the wire size to prevent excessive voltage drop. Wires should be sized for a maximum of 3% voltage drop.

CAUTION

O AVOID PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, USE

ONLY COPPER CONDUCTORS.

CAUTION

O PREVENT IMPROPER AND DANGEROUS OPERATION DUE TO WIRING ERRORS,

LABEL ALL WIRES PRI OR TO DISCONNECTION WH EN SERVICING CONTRO LS.

ERIFY PROPER OPERATION AFTER SERVICING.

NOTE: A weather-tight disconnect switch, properly sized

for the unit total load, must be field or factory installed. An external field supplied disconnect may be mounted on the exterior panel.

Ensure the data plate is not covered by the field-supplied disconnect switch.

• Some disconnect switches are not fused. Protect the power leads at the point of distribution in accordance with the unit data plate.

• The unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the latest edition of the National Electrical Code (ANSINFPA 70). A ground lug is provided for this purpose. Size grounding conductor in accordance with Table 250-95 of the National Electrical Code. Do not use the ground lug for connecting a neutral conductor.

• Connect power wiring to the compressor contactor closest to the entrance located within the main control box or to electrical power block, if equipped.

MAIN POWER

LOW VOLTAGE BLOCK

LOW VOLTAGE ENTRANCE

POWER THRU THE CURB

Power and Low Voltage Block Connections

W ARNING

AILURE OF UNIT DUE TO OPERATION ON IMPROPER LINE VOLTAGE OR WITH EXCESSIVE PHASE UNBALANCE CONSTITUTES PRODUCT ABUSE AND MAY CAUSE SEVERE DAMAGE TO THE UNIT ELECTRICAL COMPONENTS

PRODUCT DESIGN

AREAS WITHOUT CONVENIENCE OUTLET

It is recommended that an independent 115V power source be brought to the vicinity of the roof top unit for portable lights and tools used by the service mechanic.

NOTE: Refer to local codes for requirements. These outlets can also be factory installed.

UNITS INSTALLED ON ROOF TOPS

Main power and low voltage wiring may enter the unit through the condenser end of unit or through the roof curb. Install conduit connectors at the desired entrance locations. External connectors must be weatherproof. All holes in the unit base must be sealed (including those around conduit nuts) to prevent water leakage into building. All required conduit and fittings are to be field supplied.

Supply voltage to roof top unit must not vary by more than 10% of the value indicated on the unit data plate. Phase voltage unbalance must not exceed 2%. Contact your local power company for correction of improper voltage or phase unbalance.

HIGH VOLTAGE ENTRANCE

(REMOVE PLUG)

12 3/8”

30 1/4”*

* (6 Ton - 34 1/4”)

1:4

LOW VOLTAGE ENTRANCE

3.5 DIA.

POWER THRU THE CURB

4 1/2”

47 1/2”

7 1/2”

Electrical Entrance and Thru Curb

Unit is equipped with a Low Voltage Terminal Block and has Single Point wiring to the contactor or power block, if equipped.

LOW VOLTAGE CONTROL WIRING

1. A 24V thermostat must be installed for unit operation. It may be purchased with the unit or field -supplied. Thermostats may be programmable or electromechanical as required.

2. Locate thermostat or remote sensor in the conditioned space where it will sense average temperature. Do not locate the device where it may be directly exposed to supply air, sunlight or other sources of heat. Follow installation instructions packaged with the thermostat.

3. Use #18 AWG wire for 24V control wiring runs not exceeding 75 feet. Use #16 AWG wire for 24V control wiring runs not exceeding 125 feet. Use #14 AWG wire for 24V control wiring runs not exceeding 200 feet. Low voltage wiring may be National Electrical Code (NEC) Class 2 where permitted by local codes.

4. Route thermostat wires from sub-base terminals to the unit. Control wiring should enter through the condenser panel opening or through curb indicated in “Electrical Entrance” figure. Connect thermostat and any accessory wiring to low voltage terminal block TB1 in the main control box.

NOTE: Field-supplied conduit may need to be installed depending on unit/curb configuration. Use #18 AWG solid conductor wire whenever connecting thermostat wires to terminals on sub-base. DO NOT use larger than #18 AWG wire. A transition to #18 AWG wire may be required before entering thermostat sub-base.

NOTE: Refer to unit wiring diagrams for thermostat hookups.

SYSTEM OPERATION

Typical Package Cooling or Package Gas

DCC***XXX**XXX

Restrictor Orifice Assembly in Cooling Operation

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.

SYSTEM OPERATION

Typical Heat Pump System in Cooling

DCH***XXX**XXX

Reversing Valve

(Energized)

Indoor

Coil

Outdoor

Coil

Accumulator

Indoor

Coil

Accumulator

Reversing Valve

(De-Energized)

Outdoor

Coil

SYSTEM OPERATION

CIRCULATING AIR AND FILTERS

DUCTWORK

The supply duct from the unit through a wall may be installed without clearance. However, minimum unit clearances must be maintained (see “Clearances” section). The supply duct should be provided with an access panel large enough to inspect the air chamber downstream of the heat exchanger. A cover should be tightly attached to prevent air leaks.

Ductwork dimensions are shown in the roof curb installation manual.

If desired, supply and return duct connections to the unit may be made with flexible connections to reduce possible unit operating sound transmission.

VENTING

NOTE: Venting is self-contained.

CONDENSATE DRAIN CONNECTION

A 3/4” female NPT drain connection is supplied on the end of the unit and bottom of the drain pan for condensate piping. An external trap must be installed for proper condensate drainage.

DRAIN CONNECTION

UNIT 2" MIN IMUM

FLEXIBLE TUBING-HOSE OR PIPE

A POSIT IVE L I QUID SEAL IS REQU IRE D

3" MINIMUM

Drain Connection

Install condensate drain trap as shown. Use 3/4" drain line and fittings or larger. Do not operate without trap.

HORIZONTAL DRAIN

Drainage of condensate directly onto the roof may be acceptable; refer to local code. It is recommended that a small drip pad of either stone, mortar, wood or metal be provided to prevent any possible damage to the roof.

CLEANING

Due to the fact that drain pans in any air conditioning unit will have some moisture in them, algae and fungus will grow due to airborne bacteria and spores. Periodic cleaning is necessary to prevent this build-up from plugging the drain.

STARTUP, ADJUSTMENTS, AND CHECKS

WARNING

HIGH VOLTAGE!

O AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, B THE BUILDING ELECTRICAL GROUND BY USE OF THE GROUNDING TERMINAL PROVIDED OR OTHER ACCEPTABLE MEANS SERVICING OR INSTALLING THIS UNIT

OND THE FRAME OF THIS UNIT TO

. D

ISCONNECT ALL POWER BEFORE

CAUTION

PREVENT PROPERTY DAMAGE OR PERSONAL INJURY START THE UNIT UNTIL ALL NECESSARY PRE-CHECKS AND TESTS HAVE BEEN PERFORMED

, DO

NOT

WARNING

MOVING MACHIN ERY HAZARD! T

O PREVENT POSSIBLE PERSONAL INJURY OR DEATH, DISCONNECT POWER TO THE UNIT AND PADLOCK IN THE SERVICNG FANS

“OFF”

POSITION BEFORE

CONTRACTOR RESPONSIBILITY

The installing contractor must be certain that:

• All supply and return air ductwork is in place, properly

sealed, and corresponds with installation instructions.

• All thermostats are mounted and wired in accordance

with installation instructions.

• All electric power, all gas, hot water or steam line

connections, and the condensate drain installation have been made to each unit on the job. These main supply lines must be functional and capable of operating all units simultaneously.

• Requirements are met for venting and combustion air.

• Air filters are in place.

• Input rate and temperature rise are adjusted per rating

plate.

• Return air temperature is maintained between 55°F

(13°C) and 80°F (27°C).

ROOF CURB INSTALLATION CHECK

Inspect the roof curb for correct installation. The unit and curb assembly should be level. Inspect the flashing of the roof mounting curb to the roof, especially at the corners, for good workmanship. Also check for leaks around gaskets. Note any deficiencies in a separate report and forward to the contractor.

SYSTEM OPERATION

OBSTRUCTIONS, FAN CLEARANCE AND WIRING

Remove any extraneous construction and shipping materials that may be found during this procedure. Rotate all fans manually to check for proper clearances and that they rotate freely. Check for bolts and screws that may have jarred loose during shipment to the job site. Retighten if necessary. Retighten all electrical connections.

FIELD DUCT CONNECTIONS

Verify that all duct connections are tight and that there is no air bypass between supply and return.

FILTER SECTION CHECK

Remove filter section access panels and check that filters are properly installed. Note airflow arrows on filter frames.

AIR FLOW ADJUSTMENTS

When the final adjustments are complete, the current draw of the motor should be checked and compared to the full load current rating of the motor. The amperage must not exceed the service factor stamped on the motor nameplate. The total airflow must not be less than that required for operation of the electric heaters or the furnace.

If an economizer is installed, check the unit operating balance with the economizer at full outside air and at minimum outside air.

NOTE: Airflow setting below 350 CFM/Ton is not recommended, as evaporator freezing or poor unit performance is possible.

PSC MOTOR

Adjust the CFM for the unit by changing the speed tap of the indoor blower motor at the heat or cool tap on the control board connection with the one of the speed taps on “M1” or “M2” (Black-High Speed, Blue-Medium Speed, Red-Low Speed).

EEM Motor

Adjust the CFM for the unit by changing the position of the low voltage leads on the motor terminal block. Green is for Fan Only. Yellow is for Cooling and Heat Pump Heating.NOTE: If more than one lead is energized simultaneously, the motor will run at the higher speed.

SET EVAPORATOR FAN RPM

Actual RPM’s must be set and verified with a tachometer or strobe light. Refer to Appendices A and B for basic unit fan RPM. Refer also to “Airflow” section of this manual. With disconnect switch open, disconnect thermostat wires from terminals Y and W. This will prevent heating and mechanical cooling from coming on. Place a jumper wire across terminals R and G at TB1 terminal block. Close disconnect switch; evaporator fan motor will operate so RPM can be checked.

For gas heat units, the airflow must be adjusted so that the air temperature rise falls within the ranges given stated on Data Plate.

EVAPORATOR FAN ROTATION CHECK (THREE PHASE MODELS ONLY)

Check that fan rotates clockwise when viewed from the drive side of unit and in accordance with rotation arrow shown on blower housing. If it does not, reverse any two incoming power cables at Single Point Power Block. In this case, repeat bearing check.

Do not attempt to change load side wiring. Internal wiring assures all motors and compressors will rotate in correct direction once evaporator fan motor rotation check has been made.

ELECTRICAL INPUT CHECK

Make preliminary check of evaporator fan ampere draw and verify that motor nameplate amps are not exceeded. A final check of amp draw should be made upon completion of air balancing of the duct system.

BELT DRIVE MODELS ONLY

The drive on the supply fan is typically set in the middle of the RPM range. The drive motor sheave pitch diameter is field adjustable for the required airflow.

Upon completion of the air flow balancing, we recommend replacing the variable pitched motor sheave with a properlysized fixed sheave. A matching fixed sheave will provide longer belt and bearing life and vibration free operation. Initially, it is best to have a variable pitched motor sheave for the purpose of airflow balancing, but once the balance has been achieved, fixed sheaves maintain alignment and minimize vibration more effectively. For direct drive units, move fan speed wire.

BEARING CHECK

Prior to energizing any fans, check and make sure that all setscrews are tight so that bearings are properly secured to shafts.

NORMAL SEQUENCE OF OPERATION

COOLING

Begin with power turned off at all disconnects.

1. Turn thermostat system switch to “Cool,” and fan switch to “Auto” and turn temperature setting as high as it will go.

2. Inspect all registers and set them to the normal open position.

3. Turn on the electrical supply at the disconnect.

4. Turn the fan switch to the “ON” position. The blower should operate after a 7 second delay.

5. Turn the fan switch to “Auto” position. The blower should stop after a 65 second delay.

SYSTEM OPERATION

6. Slowly lower the cooling temperature until the unit starts. The compressor, blower and fan should now be operating. Allow the unit to run 10 minutes, make sure cool air is being supplied by the unit.

7. Turn the temperature setting to the highest position, stopping the unit. The indoor blower will continue to run for 65 seconds.

8. Turn the thermostat system switch to “OFF” and disconnect all power when servicing the unit.

WA RNING

HIGH VOLTAGE! D

ISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT BE PRESENT DAMAGE, PERSONAL INJURY OR DEATH

. F

. M

AILURE TO DO SO MAY CAUSE PROPERTY

ULTIPLE POWER SOURCES MAY

HEAT PUMP

9. Check the cooling mode for the heat pump in the same manner as above. The reversing valve is energized when the thermostat is placed in the cooling position. A clicking sound should be noticeable from the reversing valve. By lowering the temperature setting to call for cooling, the contractor is energized. The compressor, blower and fan should then be running. After the cooling mode is checked out, turn the thermostat system switch to “OFF”.

10.Turn the thermostat system switch to “HEAT” and fan switch to “AUTO”.

11.Slowly raise the heating temperature setting. When the heating first stage makes contact, stop raising the temperature setting.. The compressor, blower and fan should now be running with the reversing valve in the deenergized (heating) position. After giving the unit time to settle out, make sure the unit is supplying heated air.

12.If the outdoor ambient is above 80°F, the unit may trip on its high pressure cut out when on heating. The compressor should stop. The heating cycle must be thoroughly checked, so postpone the test to another day when conditions are more suitable but-DO NOT FAIL TO TEST.

If the outdoor ambient is low and the unit operates properly on the heating cycle, you may check the pressure cutout operation by blocking off the indoor return air until the unit trips.

13.If unit operates properly in the heating cycle, raise the temperature setting until the heating second stage makes contact. Supplemental resistance heat, if installed should now come on. Make sure it operates properly.

NOTE: If outdoor thermostats are installed the outdoor ambient must be below the set point of these thermostats for the heaters to operate. It may be necessary to jumper these thermostats to check heater operation if outdoor ambient is mild.

14.For thermostats with emergency heat switch, return to step 11. The emergency heat switch is located at the bottom of the thermostat. Move the switch to emergency heat. The heat pump will stop, the blower will continue to run, all heaters will come on and the thermostat emergency heat light will come on.

15.If checking the unit in the wintertime, when the outdoor coil is cold enough to actuate the defrost control, observe at least one defrost cycle to make sure the unit defrosts completely.

HEAT PUMP OPERATION

COOLING CYCLE

When the heat pump is in the cooling cycle, it operates exactly as a Summer Air Conditioner unit. In this mode, all the charts and data for service that apply to summer air conditioning apply to the heat pump. Most apply on the heating cycle except that “condenser” becomes “evaporator”, “evaporator” becomes “condenser”, “cooling” becomes “heating”.

HEATING CYCLE

The heat pump operates in the heating cycle by redirecting refrigerant flow through the refrigerant circuit external to the compressor. This is accomplished with through the reversing valve. Hot discharge vapor from the compressor is directed to the indoor coil (evaporator on the cooling cycle) where the heat is removed, and the vapor condenses to liquid. It then goes through the expansion device to the outdoor coil (condenser on the cooling cycle) where the liquid is evaporated, and the vapor goes to the compressor.

When the solenoid valve coil is operated either from heating to cooling or vice versa, the piston in the reversing valve to the low pressure (high pressure) reverse positions in the reversing valve.

The following figures show a schematic of a heat pump on the cooling cycle and the heating cycle. In addition to a reversing valve, a heat pump is equipped with an expansion device and check valve for the indoor coil, and similar equipment for the outdoor coil. It is also provided with a defrost control system.

The expansion devices are flowrator distributors and perform the same function on the heating cycle as on the cooling cycle. The flowrator distributors also act as check valves to allow for the reverse of refrigerant flow.

SYSTEM OPERATION

DEFROST CONTROL

During operation the power to the circuit board is controlled by a temperature sensor, which is clamped to a feeder tube entering the outdoor coil. Defrost timing periods of 30,60 and 90 minutes may be selected by connecting the circuit board jumper to 30, 60 and 90 respectively. Accumulation of time for the timing period selected starts when the sensor closes (approximately 31° F), and when the wall thermostat calls for heat. At the end of the timing period, the unit’s defrost cycle will be initiated provided the sensor remains closed. When the sensor opens (approximately 75° F), the defrost cycle is terminated and the timing period is reset. If the defrost cycle is not terminated due to the sensor temperature, a ten minute override interrupts the unit’s defrost period.

REFRIGERATION SYSTEM CHECKS

Ensure the hold-down bolts on the compressor are secure and have not vibrated loose during shipment. Check that vibration grommets have been installed. Visually check all piping and clamps. The entire refrigeration system has been factory charged and tested, making it unnecessary to field charge. Factory charges are shown on the unit nameplate.

When the heat pump is on the heating cycle, the outdoor coil is functioning as an evaporator. The temperature of the refrigerant in the outdoor coil must be below the temperature of the outdoor air in order to extract heat from the air. Thus, the greater the difference in the outdoor temperature and the outdoor coil temperature, the greater the heating capacity of the heat pump. This phenomenon is a characteristic of a heat pump. It is a good practice to provide supplementary heat for all heat pump installations in areas where the temperature drops below 45° F. It is also a good practice to provide sufficient supplementary heat to handle the entire heating requirement should there be a component failure of the heat pump, such as a compressor, or refrigerant leak, etc.

Since the temperature of the refrigerant in the outdoor coil on the heating cycle is generally below freezing point, frost forms on the surfaces of the outdoor coil under certain weather conditions of temperature and relative humidity. Therefore, it is necessary to reverse the flow of the refrigerant to provide hot gas in the outdoor coil to melt the frost accumulation. This is accomplished by reversing the heat pump to the cooling cycle. At the same time, the outdoor fan stops to hasten the temperature rise of the outdoor coil and lessen the time required for defrosting. The indoor blower continues to run and the supplementary heaters are energized.

FINAL SYSTEM CHECKS

1. Check to see if all supply and return air grilles are adjusted and the air distribution system is balanced for the best compromise between heating and cooling.

2. Check for air leaks in the ductwork. See Sections on Air

Flow Adjustments.

3. Make sure the unit is free of “rattles”, and the tubing in the unit is free from excessive vibration. Also make sure tubes or lines are not rubbing against each other or sheet metal surfaces or edges. If so, correct the trouble.

4. Set the thermostat at the appropriate setting for cooling and heating or automatic changeover for normal use.

5. Be sure the Owner is instructed on the unit operation, filter, servicing, correct thermostat operation, etc.

SCHEDULED MAINTENANCE

MAINTENANCE

WARNING

HIGH VOLTAGE! D

ISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT BE PRESENT DAMAGE, PERSONAL INJURY OR DEATH

. F

. M

AILURE TO DO SO MAY CAUSE PROPERTY

ULTIPLE POWER SOURCES MAY

WARNING

PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER

. FOR

CAUTION

HEET METAL PARTS, SCREWS, CLIPS AND SIMILAR ITEMS INHERENTLY HAVE SHARP EDGES, AND IT IS NECESSARY THAT THE INSTALLER AND SERVICE PERSONNEL EXERCISE CAUTION

Preventive maintenance is the best way to avoid unnecessary expense and inconvenience. Have this system inspected at regular intervals by qualified service personnel, at least twice a year. Routine maintenance should cover the following items:

1. Tighten all belts, set screws, and wire connections.

2. Clean evaporator and condenser coils mechanically or with cold water, if necessary. Usually any fouling is only matted on the entering air face of the coil and can be removed by brushing.

3. Lubricate motor bearings.

4. Align or replace belts as needed.

5. Replace filters as needed (see below).

6. Check for blockage of condensate drain.

7. Check power and control voltages.

8. Check running amperage.

9. Check operating temperatures and pressures.

10.Check and adjust temperature and pressure controls.

11.Check and adjust damper linkages.

12.Check operation of all safety controls.

13.Examine gas furnaces (see below and the User’s Information Manual).

14.Check condenser fans and tighten set screws.

ADDITIONAL

FILTERS

CAUTION

TO PREVENT PROPERTY DAMAGE DUE TO FIRE AND LOSS OF

EQUIPMENT EFFICIENCY OR EQUIPMENT DAMAGE DUE TO DUST AND LINT BUILD UP ON INTERNAL PARTS, NEVER OPERATE UNIT WITHOUT AN AIR FILTER INSTALLED IN THE RETURN AIR SYSTEM.

Every application may require a different frequency of replacement of dirty filters. Filters must be replaced at least every three (3) months during operating seasons.

Dirty filters are the most common cause of inadequate heating or cooling performance. Filter inspection should be made at least every two months; more often if necessary because of local conditions and usage.

Dirty throwaway filters should be discarded and replaced with a new, clean filter.

Disposable return air filters are supplied with this unit. See the unit Specification Sheet or the correct size and part number. To remove the filters, remove the filter access panel on return side of the unit.

CABINET FINISH MAINTENANCE

Use a fine grade automotive wax on the cabinet finish to maintain the finish’s original high luster. This is especially important in installations with extended periods of direct sunlight.

CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY)

The coil with the outside air flowing over it should be inspected annually and cleaned as frequently as necessary to keep the finned areas free of lint, hair and debris.

CONDENSER AND INDUCED DRAFT MOTORS

Bearings on the condenser fan motors and the combustion fan motor are permanently lubricated. No additional oiling is required.

LUBRICATION

The fan shaft bearings, the 1 to 2 HP supply fan motors, the condenser fan motors and compressors are permanently lubricated.

FUNCTIONAL PARTS

Refer to the unit Parts Catalog for a list of functional parts. Parts are available from your distributor.

SERVICING

S-200,20

COOLING ANALYSIS CHART

Complaint

POSSIB LE CAUSE

DOTS IN ANALYSIS

GUIDE INDICATE

"POSSIBLE CAUSE"

Power F a i lure Blown Fuse Unbalanced Power, 3PH Loose C o nne ct ion Shorted or Broken Wires Open Fan Overload Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Inter n al Compr ess or O verload Open Shorted or Grounded Compressor Compressor Stuck Faulty Compressor Contac tor Faulty Fan Relay Open Control Circuit Low Voltage Faulty Evap . Fan Motor Shorted or Grounded Fan Motor Im proper Cooling Anticipator Shortage of Refrige r ant Res tr i cted Liqu i d Line Dirty Air Filter Dirty Indoor Coil Insuffic ient air a cross Indoor Coi l Too mu ch air acros s Indoor Coil Overcharge of Refrigerant Dirty Outdoor Coil Noncondensibles Rec i rcul at ion of Condensing Ai r Infi ltration of Outdoor Air Im p ro perly Loc ated Therm osta t Air F low Un balanc ed Syst em U ndersized Bro ken Internal P ar ts Bro ken Val ves Inef fic i ent Compresso r E xpans i o n D e vice Re s tricted Loose H o l d -down Bol ts Flowrator Not Seating Properly

Compr ess or runs - goes of f on overload

Unsatisfactory

Compressor cycles on overload

Syst em runs continuo usly - little cooling

Cooling

No Cooling

SYMPTOM

System will not start

Compresso r will not start - fan runs

Com p. an d C on d. Fan wi ll no t st ar t

Evaporator fan will not start

Condenser fan will not start

•

•••

••••••

••

••• •

••

•••••

•

••

•••

•

•••

••

•• •

•• • •

••••

•• • ••

••• • •

•• • •

•••

••

•••

••

••• • • •

••

Cooling Cycle

•

System Operating Pressures

Test M et hod

Remedy

See Serv ic e Proced u re Re f.

To o c ool and the n too warm

Not coo l enough on w ar m days

Certain areas too cool, others too warm

Co m pr e s sor is no i s y

Low su ction pr essure

High suc ti on pres sure

High he ad pressure

Test Voltage S-1 Inspect Fus e Size & Type S-1 Test Voltage S-1 Inspect Connectio n - Ti gh te n S-2 , S- 3 Te st Ci rcu its Wi th Ohmmete r S-2 , S-3 Test Continuity of Overloa d S-17 A Test Continuity of Thermostat & W iring S-3 Check Control Circuit with Volt meter S-4 Test C apa citor S- 15 Test Continuity of Overloa d S-17 A Test Motor Windings S-17B Use Test Cord S-17D Test Continuit y of Coil & Contacts S-7, S-8 Test Continuit y of Coil And Contacts S-7 Test Control Circuit with Voltmeter S-4 Test Voltage S-1 Repair or Replace S-16 Test Motor Windings S-16 Check R esi st an ce of Anticipator S-3B Test For Leaks, Add Refrigerant S-101,103 Remove Restriction, Replace Restricted Part S-112 In spec t Fil ter -Cle an or Replace Inspect Coil - Clean

heck Blower Speed and Rotation, Belt, Pulleys

Reduc e Bl o wer Speed, C heck Pul ley Adjust m e nt S-205, 20 7

•

Recover Part of Charge S-113 Inspect Coil - Clean Recove r C harge, Ev acua te, Re ch ar ge S-114 Remove Obstruction to Air Flow Check Windows, Doors, V ent Fans, Etc. Relocate Thermostat Readjust Air Volume Dampers Refigure Cooling Load

•

Repl ace Com pressor S-115 Test Compressor Efficiency Test Compressor Efficiency S- 104 Remo ve Restric tion, Replace Expansi on Dev i ce 111 Ti ghten Bo lts Check Flow ra to r & Se at or Replace F l owrator S-111

S-104

SERVICING

Table of Contents

S-1 Checking Voltage.......................................... 2 0

S-2 Checking Wiring............................................ 21

S-3 Checking Thermostat, Wiring & Anticipator .. 21

S-3A Thermostat & Wiring ..................................... 21

S-3B Cooling Anticipator........................................ 21

S-4 Checking Transformer & Control Circuit ....... 21

S-7 Checking Contactor and/or Relays ................ 22

S-8 Checking Contactor Contacts .......................22

S-9 Checking Fan Relay Contact ........................ 23

S-11 Checking Loss of Charge Protection ............. 24

S-12 Checking High Pressure Control ................... 24

S-13 Checking Low Pressure Control .................... 24

S-15 Checking Capacitor......................................25

S-15A Resistance Check......................................... 25

S-15B Capacitance Check ...................................... 25

S-16 Checking Motors........................................... 26

S-16A Checking Fan & Blower Motor

Windings (PSC Motors) ............................... 26

S-16D Checking EEM Motors .................................. 26

S-17 Checking Compressor Windings .................. 27

S-17A Resistance Test ............................................27

S-17B Ground Test .................................................. 27

S-17D Operation Test ..............................................28

S-18 Testing Crankcase Heater (optional item).....28

S-18A Crankcase Heater Thermostat ...................... 28

S-21 Checking Reversing Valve & Solenoid.......... 28

S-24 Testing Defrost Control .................................29

S-25 Testing Defrost Thermostat ........................... 29

S-50 Checking Heater Limit Control(s).................. 30

S-100 Refrigeration Repair Practice ....................... 30

S-101 Leak Testing ................................................. 30

S-102 Evacuation .................................................... 31

S-103 Charging.......................................................32

S-104 Checking Compressor Efficiency ................. 33

S-106 Overfeeding .................................................. 33

S-108 Checking Superheat ..................................... 33

S-111 Fixed Orifice Restriction Devices.................. 36

S-112 Checking Restricted Liquid Line ................... 36

S-113 Refrigerant Overcharge ................................ 36

S-114 Non-condensables ........................................ 36

S-115 Compressor Burnout.....................................36

S-200 Checking External Static Pressure ...............37

S-201 Checking Temperature Rise .........................39

S-205 Checking Belt Tension .................................. 38

S-206 Indoor Fan Rotation Check ........................... 39

S-207 Motor Sheave Adjustment ............................. 39

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, person al inj ury or death.

SERVICING

S-1 CHECKING VOLTAGE

HIGH VOLTAGE! Disconnect ALL power before servicing or insta llin g th is un it. M ult iple powe r sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Remove doors, control panel cover, etc. from unit being tested.

With power ON:

WARNING

Line Voltage now present.

2. Using a voltmeter, measure the voltage across terminals L1 and L2 of the contactor for single phase units, and L3, for 3 phase units.

3. No reading - indicates open wiring, open fuse(s) no power or etc. from unit to fused disconnect service. Repair as needed.

4. With ample voltage at line voltage connectors, energize the unit.

5. Measure the voltage with the unit starting and operating, and determine the unit Locked Rotor Voltage.

Locked Rotor Voltage is the actual voltage available at the compressor during starting, locked rotor, or a stalled condition. Measured voltage should be above minimum listed in chart below.

To measure Locked Rotor Voltage attach a voltmeter to the run "R" and common "C" terminals of the compressor, or to the T1 and T2 terminals of the contactor. Start the unit and allow the compressor to run for several seconds, then shut down the unit. Immediately attempt to restart the unit while measuring the Locked Rotor Voltage.

6. Voltmeter should read within the voltage tabulation as shown. If the voltage falls below the minimum voltage, check the line wire size. Long runs of undersized wire can cause low voltage. If wire size is adequate, notify the local power company in regards to either low or high voltage.

Unit Supply Voltage

Voltage Min. Max.

208/230 198 253

400 360 440 460 437 506

575 546 604

Three phase units require a balanced 3 phase power supply to operate. If the percentage of voltage imbalance exceeds 3% the unit must not be operated until the voltage condition is corrected.

Max. Voltage Deviation % Voltage = From Average Voltage X 100 Imbalance Average Voltage

To find the percentage of imbalance, measure the incoming power supply.

L1 - L2 = 240V L1 - L3 = 232V Avg. V = L2 - L3 =

238V 3

710 = 236.7

Total 710V

To find Max. deviation: 240 - 236.7 = +3.3

232 - 236.7 = -4.7

238 - 236.7 = +1.3 Max deviation was 4.7V % Voltage Imbalance = 4.7 = 1.99%

236.7

If the percentage of imbalance had exceeded 3%, it must be determined if the imbalance is in the incoming power supply or the equipment. To do this rotate the legs of the incoming power and retest voltage as shown below.

L1 - L2 = 240V L1 - L3 = 227V L2 - L3 = 238V

L1 L2

L3L2

Ro tate all 3 incomin g legs as shown.

L1 - L2 = 227V L1 - L3 = 238V L2 - L3 = 240V

By the voltage readings we see that the imbalance rotated or traveled with the switching of the incoming legs. Therefore the imbalance lies within the incoming power supply.

If the imbalance had not changed then the problem would lie within the equipment. Check for current leakage, shorted motors, etc.

SERVICING

S-2 CHECKING WIRING

HIGH VOL TAGE! Disconnect ALL power before servicing or insta llin g this uni t. M ultip le po wer sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Check wiring visually for signs of overheating, damaged insulation and loose connections.

2. Use an ohmmeter to check continuity of any suspected open wires.

3. If any wires must be replaced, replace with comparable gauge and insulation thickness.

S-3 CHECKING THERMOSTAT, WIRING, AND

ANTICIPATOR

THERMO ST AT WIRE SIZI NG CHART

LENGTH OF RUN

25 fe et 18 50 fe et 16

75 fe et 14 100 fe et 14 125 fe et 12 150 fe et 12

M IN. COPPER WI RE

GAUGE (AWG)

S-3A THERMOSTAT AND WIRING

4. Check the continuity of the thermostat and wiring. 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 before the system is restarted. A properly sized anticipator should maintain room temperature within 1 1/2 to 2 degree range.

The anticipator is supplied in the thermostat and is not to be replaced. If the anticipator should fail for any reason, the thermostat must be changed.

S-4 CHECKING TRANSFORMER

AND CONTROL CIRCUIT

HIGH VOLTAGE! Disconnect ALL power before servicing or insta llin g th is un it. M ult iple powe r sources may be present. Failure to do so may cause property damage, personal injury or death.

A step-down transformer (either 208-240, 460 or 575 volt primary to 24 volt secondary) is provided with each unit. This allows ample capacity for use with resistance heaters.

WARNING

Line Voltage now present.

With power ON, thermostat calling for cooling

1. Use a voltmeter to check for 24 volts at thermostat wires C and Y in the unit control panel.

2. No voltage indicates trouble in the thermostat or wiring.

3. Check the continuity of the thermostat and wiring. Repair or replace as necessary.

Indoor Blower Motor

With power ON:

WARNING

Line Voltage now present.

1. Set fan selector switch at thermostat to "ON" position.

2. With voltmeter, check for 24 volts at wires C and G.

3. No voltage indicates the trouble is in the thermostat or wiring.

WARNING

Disconnect ALL power before servicing.

1. Remove control panel cover to gain access to transformer.

With power ON:

WARNING

Line Voltage now present.

2. Using a voltmeter, check voltage across secondary voltage side of transformer (R to C).

3. No voltage indicates faulty transformer, bad wiring, or bad splices.

4. Check transformer primary voltage at incoming line voltage connections and/or splices.

5 If line voltage available at primary voltage side of trans-

former and wiring and splices good, transformer is inoperative. Replace.

SERVICING

S-7 CHECKING CONTACTOR AND/OR RELAYS

HIGH VOLTAGE! Disconnect ALL power before servicing or insta llin g th is un it. M ult iple powe r sources may be present. Failure to do so 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 normal position.

NOTE: Most single phase contactors break only one side of the line (L1), leaving 115 volts to ground present at most internal components.

1. Remove the leads from the holding coil.

2. Using an ohmmeter, test across the coil terminals. If the coil does not test continuous, replace the relay or

contactor.

S-8 CHECKING CONTACTOR CONTACTS

SINGLE PHASE

HIGH VOL TAGE! Disconnect ALL power before serv icing or installing this unit. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

VOLT/OHM

METER

L1L2

Ohmmete r fo r te st in g h oldi n g coil Voltmeter for testing contacts

TESTING COMPRESSOR CONTACTOR

(Single Phase)

3. Using a voltmeter, test across terminals. A. L1 - L2 - No voltage. Check breaker or fuses on main

power supply.

B. L2 - T1 - No voltage indicates CC1 contacts open.

If a no voltage reading is obtained - replace the contactor.

THREE PHASE

Using a voltmeter, test across terminals.

A. L1-L2, L1-L3, and L2-L3 - If voltage is present,

proceed to B. If voltage is not present, check breaker or fuses on main power supply..

B. T1-T2, T1-T3, and T2-T3 - If voltage readings are not

the same as in "A", replace contactor.

T3L3T2

1. Disconnect the wire leads from the terminal (T) side of the contactor.

2. With power ON, energize the contactor.

VOLT/OHM

METER

Ohmmeter for testing holding coil Voltmeter for testing contacts

TESTING COMPRESSOR CONTACTOR

(ThreePhase)

SERVICING

S-9 CHECKING FAN RELAY CONTACTS

DCG:

The fan relays are incorporated into the control board. See section S-313 for checking control board for single phase gas models.

For 3 phase and belt drive models, the procedure for testing the fan relay contacts will be the same as checking the compressor contactor contacts (See section S-8).

DCC/DCH:

The Electronic Blower Time Delay Relay is used on PSC and belt driven models.

HIGH VOL TAGE! Disconnect ALL power before servicing or inst all in g this u nit. M ult ip le po wer sources may be present. Failure to do so may cause property damage, personal injury or death.

Checking EBTDR High Voltage Contacts

1. With power off, remove wires from terminals NC, COM, and NO.

2. Using a VOM, check for resistance from NO to COM. Should read open. Next, check for resistance from NC to COM. Should read closed.

3. If not as above, replace EBTDR.

PSC equipped, single phase model coolers and heat pumps have an isolation relay with a 240 volt holding coil in addition to the EBTDR.

WARNING

Disconnect ALL power before servicing.

Turn power off.

Testing relay holding coil

1. Remove the leads from the holding coil terminals 1 and

2. Using an ohmmeter, test across the coil terminals 1 and

3. If the coil does not test continuous, replace the relay.

Testing relay contacts

WARNING

Disconnect ALL power before servicing.

Turn power off.

1. Using a VOM, test resistance across relay terminals 2 and 4. Should read open.

2. Turn power on.

Checking EBTDR Contact Operation

With power on:

1. Set the thermostat to the fan "on" position.

2. Check for 24 volts at the C and G terminals of the EBTDR.

3. If no voltage present, check fan circuit from thermostat. If 24 volts present, proceed to step 4.

4. Using a VOM, check for line voltage from the purple wire at the transformer (terminal 3 on 240 volt units, terminal 2 on 208 volt units) to terminal NO on the EBTDR. Should read line voltage. If no voltage present, check line voltage wiring in unit. If line voltage present, proceed to step 5.

5. Using a VOM, check for line voltage from the purple wire at the transformer (terminal 3 on 240 volt units, terminal 2 on 208 volt units) to the COM terminal on the EBTDR. Should read line voltage. If not as above, replace EBTDR.

3. Apply 240 volts to coil terminals 1 and 3.

4. Using a VOM, check for 240 volts from terminals 3 and 1 of relay. Should read 240 volts. If voltage present, proceed to step 5.

5. Using a VOM, check for 240 volts from L1 at contactor to terminal 4 of relay. Should read 240 volts. Next check from L1 at contactor to terminal 2 of relay. Should read 240 volts.

If not as above, replace relay. On the 5 ton units with the EEM motor, a standard fan relay

is used.

WARNING

Disconnect ALL power before servicing.

Turn power off.

SERVICING

Testing relay holding coil

1. Remove the leads from the holding coil.

2. Using an ohmmeter, test across the coil terminals 1 and

3. If the coil does not test continuous, replace the relay.

Testing relay contacts

WARNING

Disconnect ALL power before servicing.

Turn power off.

1. Using a VOM, test resistance across relay terminals 2 and 4. Should read open.

2. Turn power on.

3. Apply 24 volts to coil terminals 1 and 3.

4. Using a VOM, check for 24 volts from terminals 3 and 2 of relay. Should read 24 volts. If no voltage, check low voltage wiring from transformer to relay. If voltage present, proceed to step 5.

5. Using a VOM, check for 24 volts from terminals 3 and 4 of relay. Should read 24 volts.

If not as above, replace relay.

S-11 CHECKING LOSS OF CHARGE PROTEC-

TOR

S-12 CHECKING HIGH PRESSURE CONTROL

HIGH VOLTAGE! Disconnect ALL power before servicing or insta llin g th is un it. M ult iple powe r sources may be present. Failure to do so may cause property damage, personal injury or death.

The high pressure control senses the pressure in the discharge line. If abnormally high discharge pressures develop, the contacts of the control open, breaking the control circuit before the compressor motor overloads. This control is automatically reset.

1. Using an ohmmeter, check across terminals of high pressure control, with wire removed. If not continuous, the contacts are open.

3. Attach a gauge to the access fitting on the liquid line.

With power ON:

4. Start the system and place a piece of cardboard in front of the condenser coil, raising the condensing pressure.

5. Check pressure at which the high pressure control cutsout.

(Heat Pump Models)

The loss of charge protector senses the pressure in the liquid line and will open its contacts on a drop in pressure. The low pressure control will automatically reset itself with a rise in pressure.

The low pressure control is designed to cut-out (open) at approximately 22 PSIG. It will automatically cut-in (close) at approximately 50 PSIG.

Test for continuity using a VOM and if not as above, replace the control.

If it cuts-out at 660 PSIG ± 10 PSIG, it is operating normally (See causes for high head pressure in Service Problem Analysis Guide). If it cuts out below this pressure range, replace the control. The control should reset at 420 PSIG ± 25 PSIG.

SERVICING

S-13 CHECKING LOW PRESSURE CONTROL

The low pressure control senses the pressure in the suction line and will open its contacts on a drop in pressure. The low pressure control will automatically reset itself with a rise in pressure.

The low pressure control is designed to cut-out (open) at approximately 22 PSIG ± 7 PSIG. It will automatically cut-in (close) at approximately 50 PSIG ± 7 PSIG.

Test for continuity using a VOM and if not as above, replace the control.

S-15 CHECKING CAPACITOR

CAPACITOR, RUN

A run capacitor is wired across the auxiliary and main windings of a single phase permanent split capacitor motor. The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor. This is accomplished by using the 90° phase relationship between the capacitor current and voltage in conjunction with the motor windings so that the motor will give two phase operation when connected to a single phase circuit. The capacitor also reduces the line current to the motor by improving the power factor.

CAPACITOR, START SCROLL COMPRESSOR MODELS

Hard start components are not required on Scroll compressor equipped units due to a non-replaceable check valve located in the discharge line of the compressor. However hard start kits are available and may improve low voltage starting characteristics.

This check valve closes off high side pressure to the compressor after shut down allowing equalization through the scroll flanks. Equalization requires only about one or two seconds during which time the compressor may turn backwards.

Your unit comes with a 180-second anti-short cycle to prevent the compressor from starting and running backwards.

MODELS EQUIPPED WITH A HARD START DEVICE

A start capacitor is wired in parallel with the run capacitor to increase the starting torque. The start capacitor is of the electrolytic type, rather than metallized polypropylene as used in the run capacitor.

A switching device must be wired in series with the capacitor to remove it from the electrical circuit after the compressor starts to run. Not removing the start capacitor will overheat the capacitor and burn out the compressor windings.

These capacitors have a 15,000 ohm, 2 watt resistor wired across its terminals. The object of the resistor is to discharge the capacitor under certain operating conditions, rather than having it discharge across the closing of the contacts within the switching device such as the Start Relay, and to reduce the chance of shock to the servicer. See the Servicing Section for specific information concerning capacitors.

RELAY, START

A potential or voltage type relay is used to take the start capacitor out of the circuit once the motor comes up to speed. This type of relay is position sensitive. The normally closed contacts are wired in series with 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 before servicing or insta llin g this un it. M ult iple powe r sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Discharge capacitor and remove wire leads.

WARNING

Discharge capacitor through a 20 to 30 OHM resistor before handling.

OHMMETER

CAPACITOR

TESTING CAPACITOR RESISTANCE

2. Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor -

a. Good Condition - indicator swings to zero and

slowly returns to infinity. (Start capacitor with bleed resistor will not return to infinity. It will still read the resistance of the resistor).

b. Shorted - indicator swings to zero and stops there

-replace.

c. Open - no reading - replace. (Start capacitor

would read resistor resistance.)

SERVICING

S-15B CAPACITANCE CHECK

Using a hookup as shown below, take the amperage and voltage readings and use them in the formula:

HIGH VOLTAGE! Disconnect ALL power before servicing or insta llin g th is un it. M ult iple powe r sources may be present. Failure to do so may cause property damage, personal injury or death.

VOLTMETER

15 AMP

FUSE

AMMETER

CAPACITOR

TESTING CAPACITANCE

WARNING

Discharge capacitor through a 20 to 30 OHM resistor before handling.

Capacitance (MFD) = 2650 X Amperage

Voltage

S-16 CHECKING MOTORS S-16A CHECKING FAN AND BLOWER MOTOR

WINDINGS (PSC MOTORS)

1. Remove the motor leads from its respective connection points and capacitor (if applicable).

2. Check the continuity between each of the motor leads.

3. Touch one probe of the ohmmeter to the motor frame (ground) and the other probe in turn to each lead.

If the windings do not test continuous or a reading is obtained from lead to ground, replace the motor.

S-16D CHECKING EEM (ENERGY EFFICIENT MOTOR) MOTORS

Applies only to units with EEM Motors

The EEM Motor is a one piece, fully encapsulated, 3 phase brushless DC (single phase AC input) motor with ball bearing construction. Unlike the ECM 2.3/2.5 motors, the EEM features an integral control module.

Note: The GE TECMate will not currently operate the GE EEM motor.

1. Using a voltmeter, check for 230 volts to the motor connections L and N. If 230 volts is present, proceed to step 2. If 230 volts is not present, check the line voltage circuit to the motor.

2. Using a voltmeter, check for 24 volts from terminal C to either terminal 1, 2, 3, 4, or 5, depending on which tap is being used, at the motor. If voltage present, proceed to step 3. If no voltage, check 24 volt circuit to motor.

3. If voltage was present in steps 1 and 2, the motor has failed and will need to be replaced.

Applies only to units with PSC Motors

The auto reset fan motor overload is designed to protect the motor against high temperature and high amperage conditions by breaking the common circuit within the motor, similar to the compressor internal overload. However, heat generated within the motor is faster to dissipate than the compressor, allow at least 45 minutes for the overload to reset, then retest.

Note: When replacing motor, ensure the belly band is between the vents on the motor and the wiring has the proper drip loop to prevent condensate from entering the motor.

SERVICING

High Voltage Connections

3/16"

LGN

S-17A RESISTANCE TEST

Each compressor is equipped with an internal overload. The line break internal overload senses both motor amperage

and winding temperature. High motor temperature or amperage heats the disc causing it to open, breaking the common circuit within the compressor on single phase units.

Heat generated within the compressor shell, usually due to recycling of the motor, high amperage or insufficient gas to cool the motor, is slow to dissipate. Allow at least three to four hours for it to cool and reset, then retest.

123

Low Voltage Connections

1/4”

EEM MOTOR CONNECTIONS

S-17 CHECKING COMPRESSOR WINDINGS

WARNING

Hermetic compressor electrical terminal venting can be dangerous. When insulating material which supports a hermetic compressor or electrical terminal suddenly disintegrates due to physical abuse or as a result of an electrical short between the terminal and the compressor housing, the terminal may be expelle d, ve nting th e vap or a nd liq uid co nten ts of the compressor housing and system.

If the compressor terminal PROTECTIVE COVER and gasket (if required) are not properly in place and secured, there is a remote possibility if a terminal vents, that the vaporous and liquid discharge can be ignited, spouting flames several feet, causing potentially severe or fatal injury to anyone in its path.

This discharge can be ignited external to the compressor if the terminal cover is not properly in place and if the discharge impinges on a sufficient heat source.

Ignition of the discharge can also occur at the venting terminal or inside the compressor, if there is sufficient contaminant air present in the system and an electrical arc occurs as the terminal vents.

Ignition cannot occur at the venting terminal without the presence of contaminant air, and cannot occur externally from the venting terminal without the presence of an external ignition source.

Therefore, proper evacuation of a hermetic system is essential 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 extinguished or turned off prior to servicing a system.

HIGH VOLTAGE! Disconnect ALL power before servicing or insta llin g th is un it. M ult iple powe r sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Remove the leads from the compressor terminals.

See warnings S-17 before removing compressor terminal cover .

2. Using an ohmmeter, test continuity between terminals SR, C-R, and C-S, on single phase units or terminals T1, T2 and T3, on 3 phase units.

OHMMETER

TESTING COMPRESSOR WINDINGS

If either winding does not test continuous, replace the compressor.

NOTE: If an open compressor is indicated, allow ample time for the internal overload to reset before replacing compressor.

COMP

S-17B GROUND TEST

If fuse, circuit breaker, ground fault protective device, etc., has tripped, this is a strong indication that an electrical problem exists and must be found and corrected. The circuit protective device rating must be checked, and its maximum rating should coincide with that marked on the equipment nameplate.

SERVICING

With the terminal protective cover in place, it is acceptable to replace the fuse or reset the circuit breaker ONLY to see if it was just a nuisance opening. If it opens again,

DO NOT continue to reset.

WARNING

Disconnect ALL power before servicing.

ONE TIME

HIGH VOL TAGE! Disconnect ALL power before servicing or insta llin g this uni t. M ultip le po wer sources may be present. Failure to do so may cause property damage, personal injury or death.

Disconnect all power to unit, making sure that all power

legs are open.

1. DO NOT remove protective terminal cover. Disconnect the three leads going to the compressor terminals at the nearest point to the compressor.

2. Identify the leads and using a Megger, Hi-Potential Ground Tester, or other suitable instrument which puts out a voltage between 300 and 1500 volts, check for a ground separately between each of the three leads and ground (such as an unpainted tube on the compressor). Do not use a low voltage output instrument such as a voltohmmeter.

HI-POT

COMPRESSOR GROUND TEST

3. If a ground is indicated, then carefully remove the compressor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires.

4. If no visual problems indicated, carefully remove the leads 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.

Carefully retest for ground, directly between compressor terminals and ground.

5. If ground is indicated, replace the compressor.

S-17D OPERATION TEST

If the voltage, capacitor, overload and motor winding test fail to show the cause for failure:

1. Remove unit wiring from disconnect switch and wire a test cord to the disconnect switch.

NOTE: The wire size of the test cord must equal the line wire size and the fuse must be of the proper size and type.

2. With the protective terminal cover in place, use the three leads to the compressor terminals that were disconnected at the nearest point to the compressor and connect the common, start and run clips to the respective leads.

3. Connect good capacitors of the right MFD and voltage rating into the circuit as shown.

4. With power ON, close the switch.

WARNING

Line Voltage now present.

A.If the compressor starts and continues to run, the cause

for failure is somewhere else in the system.

B.If the compressor fails to start - replace.

S-18 TESTING CRANKCASE HEATER (OP-

TIONAL ITEM)

Note: Not all compressors use crankcase heaters.

The crankcase heater must be energized a minimum of twenty-four (24) hours before the compressor is operated.

Crankcase heaters are used to prevent migration or accumulation of refrigerant in the compressor crankcase during the off cycles and prevents liquid slugging or oil pumping on start up. On some models, the crankcase heater is controlled by a crankcase heater thermostat that is wired in series with the crankcase heater.

A crankcase heater will not prevent compressor damage due to a floodback or over charge condition.

WARNING

Disconnect ALL power before servicing.

1. Disconnect the heater lead in wires.

2. Using an ohmmeter, check heater continuity - should test continuous. If not, replace.

SERVICING

S-18A CHECKING CRANKCASE HEATER THER-

MOSTAT

Note: Not all models with crankcase heaters will have a

crankcase heater thermostat.

1. Install a thermocouple type temperature test lead on the discharge line adjacent to the crankcase heater thermostat.

2. Check the temperature at which the control closes its contacts by lowering the temperature of the control. The crankcase heater thermostat should close at 67°F ± 5°F.

3. Check the temperature at which the control opens its contacts by raising the temperature of the control. The crankcase heater thermostat should open at 85°F ± 5°F.

4. If not as above, replace control.

S-21 CHECKING REVERSING VALVE AND SOLE-

NOID

Occasionally the reversing valve may stick in the heating or cooling position or in the mid-position.

When stuck in the mid-position, part of the discharge gas from the compressor is directed back to the suction side, resulting in excessively high suction pressure. An increase in the suction line temperature through the reversing valve can also be measured. Check operation of the valve by starting the system and switching the operation from COOLING to HEATING cycle.

If the valve fails to change its position, test the voltage (24V) at the valve coil terminals, while the system is on the COOLING cycle.

If no voltage is registered at the coil terminals, check the operation of the thermostat and the continuity of the connecting wiring from the "O" terminal of the thermostat to the unit.

If voltage is registered at the coil, tap the valve body lightly while switching the system from HEATING to COOLING, etc. If this fails to cause the valve to switch positions, remove the coil connector cap and test the continuity of the reversing valve solenoid coil. If the coil does not test continuous replace it.

If the coil test continuous and 24 volts is present at the coil terminals, the valve is inoperative - replace it.

5. Using VOM check for voltage across terminals "C & O". Meter should read 24 volts.

6. Using VOM check for voltage across fan terminals DF1 and DF2 on the board. You should read line voltage (208230 VAC) indicating the relay is open in the defrost mode.

7. Using VOM check for voltage across "W2 & C" terminals on the board. You should read 24 volts.

8. If not as above, replace control board.

9. Set thermostat to off position and disconnect power before removing any jumpers or wires.

NOTE: Remove jumper across defrost thermostat before returning system to service.

S-25 TESTING DEFROST THERMOSTAT

1. Install a thermocouple type temperature test lead on the tube adjacent to the defrost control. Insulate the lead point of contact.

2. Check the temperature at which the control closes its contacts by lowering the temperature of the control. On 2 and 2.5 ton units, it should close at 34°F ± 5°F. On 3 thru 5 ton units, it should close at 31°F ± 3°F.

3. Check the temperature at which the control opens its contacts by raising the temperature of the control. On 2 and 2.5 ton units, it should open at 60°F ± 5°F. On 3 thru 5 ton units, it should open at 75°F ± 6°F.

4. If not as above, replace control.

TROUBLESHOOTING

THE FOLLOWING INFORMATION IS FOR USE BY QUALIFIED SERVICE AGENCY ONLY: OTHERS SHOULD NOT ATTEMPT TO SERVICE THIS EQUIPMENT.

Common Causes of Unsatisfactory Operation of Heat Pump on the Heating Cycle.

INADEQUATE AIR VOLUME THROUGH INDOOR COIL

When a heat pump is in the heating cycle, the indoor coil is functioning as a condenser. The return air filter must always be clean, and sufficient air volume must pass through the indoor coil to prevent excessive discharge pressure, and high pressure cut out.

S-24 TESTING DEFROST CONTROL

To check the defrost control for proper sequencing, proceed as follows: With power ON; unit not running.

1. Jumper defrost thermostat by placing a jumper wire across the terminals "DFT" and "R" at defrost control board.

2. Connect jumper across test pins on defrost control board.

3. Set thermostat to call for heating. System should go into defrost within 21 seconds.

4. Immediately remove jumper from test pins.

OUTSIDE AIR INTO RETURN DUCT

Do not introduce cold outside air into the return duct of a heat pump installation. For units with 2-speed motors, do not allow air entering the indoor coil to drop below 65° F. Air below this temperature will cause low discharge pressure, thus low suction pressure, and excessive defrost cycling resulting in low heating output. It may also cause false defrosting.

SERVICING

NDERCHARGE

An undercharged heat pump on the heating cycle will cause low discharge pressure resulting in low suction pressure and frost accumulation on the outdoor coil.

POOR “TERMINATING” SENSOR CONTACT

The unit’s defrost terminating sensor must make good thermal contact with the outdoor coil tubing. Poor contact may not terminate the unit’s defrost cycle quickly enough to prevent the unit from cutting out on high discharge pressure.

MALFUNCTIONING REVERSING VALVE - THIS MAY BE DUE

1. Solenoid not energized - In order to determine if the solenoid is energized, touch the nut that holds the solenoid cover in place with a screwdriver. If the nut magnetically holds the screwdriver, the solenoid is energized and the unit is in the cooling cycle.

2. No voltage at unit’s solenoid - Check unit voltage. If no voltage, check wiring circuit.

3. Valve will not shift:

a. Undercharged - check for leaks; b. Valve Body Damaged - Replace valve; c. Unit Properly Charged - If it is on the heating cycle,

raise the discharge pressure by restricting airflow through the indoor coil. If the valve does not shift, tap it lightly on both ends with a screwdriver handle. DO NOT TAP THE VALVE BODY. If the unit is on the cooling cycle, raise the discharge pressure by restricting airflow through the outdoor coil. If the valve does not shift after the above attempts, cut the unit off and wait until the discharge and suction pressure equalize, and repeat above steps. If the valve does not shift, replace it.

S-100 REFRIGERATION REPAIR PRACTICE

DANGER

Always remove the refrigerant charge in a proper manner before applying heat to the system.

When repairing the refrigeration system:

WARNING

Disconnect ALL power before servicing.

1. Never open a system that is under vacuum. Air and moisture will be drawn in.

2. Plug or cap all openings.

3. Remove all burrs and clean the brazing surfaces of the tubing with sand cloth or paper. Brazing materials do not flow well on oxidized or oily surfaces.

4. Clean the inside of all new tubing to remove oils and pipe chips.

5. When brazing, sweep the tubing with dry nitrogen to prevent the formation of oxides on the inside surfaces.

6. Complete any repair by replacing the liquid line drier in the system, evacuate and charge.

BRAZING MATERIALS

Copper to Copper Joints - Sil-Fos used without flux (alloy of 15% silver, 80% copper, and 5% phosphorous). Recommended heat 1400°F.

Copper to Steel Joints - Silver Solder used without a flux (alloy of 30% silver, 38% copper, 32% zinc). Recommended heat - 1200°F.

S-50 CHECKING HEATER LIMIT CONTROL(S)

(OPTIONAL ELECTRIC HEATERS)

Each individual heater element is protected with an automatic rest limit control connected in series with each element to prevent overheating of components in case of low airflow. This limit control will open its circuit at approximately 150°F. to 160°F and close at approximately 110°F.

WARNING

Disconnect ALL power before servicing.

1. Remove the wiring from the control terminals.

2. Using an ohmmeter test for continuity across the normally closed contacts. No reading indicates the control is open - replace if necessary. Make sure the limits are cool before testing.

IF FOUND OPEN - REPLACE - DO NOT WIRE AROUND.

S-101 LEAK TESTING

(NITROGEN OR NITROGEN-TRACED)

WARNING

To avoid the risk of fire or explosion, never use oxygen, high pressure air or flammable gases for leak testing of a refrigeration system.

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Daikin DCH090, DCC060, DCH060, DCH072, DCH102 Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual