Daikin DP 13, DP 14 User Manual

Service Instructions

DP 13 and 14 SEER PACKAGE HEA T PUMPS

DP 13 and 14 PACKAGE COOLING

HORIZONTAL MODELS

WITH R-410A

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.

RSD6300011r3

April 2016

INDEX

IMPORT ANT INFORMA TION ......................................................................................................... 4 - 5

PRODUCT IDENTIFICATION - DP[13-14]C/HH**41** ................................................................. 6 - 7

ACCESSORIES................................................................................................................................... 8

PCCP101-103 ROOF CURB .......................................................................................................................................... 9

PCP101-103 DOWNFLOW PLENUM ............................................................................................................................ 9

PCEF101-103 ELBOW AND FLASHING KIT ............................................................................................................... 10

DDNECNJPCHHA ECONOMIZER ................................................................................................................................10

PCMD101-103 DOWNFLOW MANUAL DAMPER ........................................................................................................11

GPHMD101-103 HORIZONTAL MOTORIZED DAMPER WITH DUCT FLANGE ............................................................11

SQRPC SQUARE TO ROUND CONVERTER............................................................................................................... 12

SQRPCH SQUARE TO ROUND CONVERTER ............................................................................................................ 12

DPHRFA EXTERNAL FIL TER KIT ............................................................................................................................... 13

PRODUCT DESIGN .......................................................................................................................... 14

ELECTRICAL WIRING ................................................................................................................................................. 15

LINE VOL T AGE WIRING.............................................................................................................................................. 16

SYSTEM OPERATION ...................................................................................................................... 17

DP[13-14]C/HH**41**

COOLING.................................................................................................................................................................... 17

COOLING CYCLE........................................................................................................................................................ 17

HEA TING CYCLE......................................................................................................................................................... 17

DEFROST CYCLE ....................................................................................................................................................... 18

FAN OPERA TION ........................................................................................................................................................ 18

SCHEDULED MAINTENANCE ......................................................................................................... 21

ONCE A MONTH ......................................................................................................................................................... 21

ONCE A YEAR............................................................................................................................................................. 21

TEST EQUIPMENT...................................................................................................................................................... 21

SERVICING ....................................................................................................................................... 22

COOLING/HEA T PUMP- SERVICE ANALYSIS GUIDE ................................................................................................ 22

S-1 CHECKING VOL TAGE ........................................................................................................................................... 23

S-2 CHECKING WIRING .............................................................................................................................................. 23

S-3 CHECKING THERMOSTAT , WIRING , AND ANTICIP A TOR.................................................................................... 23

S-3A Thermostat and Wiring ..................................................................................................................................... 23

S-3B Cooling Anticipator ........................................................................................................................................... 24

S-3C Heating Anticipator ........................................................................................................................................... 24

S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT ....................................................................................... 24

S-7 CHECKING CONT ACTOR AND/OR RELA YS........................................................................................................ 24

S-8 CHECKING CONT ACTOR CONTACTS.................................................................................................................. 25

S-9 CHECKING FAN RELA Y CONT ACTS..................................................................................................................... 25

S-11 CHECKING LOSS OF CHARGE PROTECT OR ................................................................................................... 26

S-15 CHECKING CAP ACITOR ..................................................................................................................................... 26

S-15A RESIST ANCE CHECK ....................................................................................................................................... 27

S-15B CAP ACITANCE CHECK ..................................................................................................................................... 27

S-16 CHECKING MOTORS .......................................................................................................................................... 28

S-16A CHECKING F AN AND BLOWER MOTOR WINDINGS (PSC MOT ORS) ............................................................ 28

S-16D CHECKING EEM MOTORS ............................................................................................................................... 28

S-17 CHECKING COMPRESSOR WINDINGS ............................................................................................................. 29

S-17A RESIST ANCE TEST .......................................................................................................................................... 29

S-17B GROUND TEST ................................................................................................................................................. 29

S-17D Operation T est ................................................................................................................................................. 30

S-18 TESTING CRANKCASE HEA TER ........................................................................................................................ 30

S-18A CHECKING CRANKCASE HEA TER THERMOST AT........................................................................................... 30

INDEX

S-21 CHECKING REVERSING V AL VE AND SOLENOID .............................................................................................. 30

S-24 TESTING DEFROST CONTROL .......................................................................................................................... 31

S-25 TESTING DEFROST THERMOSTA T.................................................................................................................... 31

S-50 CHECKING HEA TER LIMIT CONTROL(S) ........................................................................................................... 31

S-52 CHECKING HEA TER ELEMENTS ........................................................................................................................ 31

S-100 REFRIGERA TION REPAIR PRACTICE............................................................................................................... 32

S-101 LEAK TESTING ................................................................................................................................................. 32

S-102 EV ACUATION..................................................................................................................................................... 32

S-103 CHARGING ........................................................................................................................................................ 33

S-104 CHECKING COMPRESSOR EFFICIENCY ......................................................................................................... 34

S-108 SUPERHEA T ...................................................................................................................................................... 34

S-109 CHECKING SUBCOOLING ................................................................................................................................35

S-11 1 FIXED ORIFICE RESTRICTION DEVICES ......................................................................................................... 35

S-112 CHECKING RESTRICTED LIQUID LINE ............................................................................................................ 36

S-113 REFRIGERANT OVERCHARGE ......................................................................................................................... 36

S-114 NON-CONDENSABLES...................................................................................................................................... 36

S-115 COMPRESSOR BURNOUT................................................................................................................................39

S-122 REVERSING V ALVE REPLACEMENT................................................................................................................ 39

S-200 CHECKING EXTERNAL ST ATIC PRESSURE .................................................................................................... 40

S-201 CHECKING TEMPERA TURE RISE ..................................................................................................................... 40

WIRING DIAGRAMS.......................................................................................................................... 41

OT18-60A OUTDOOR THERMOST A T ......................................................................................................................... 41

OT18-60A OUTDOOR THERMOST A T ......................................................................................................................... 42

SINGLE PHASE HKR** HEAT KITS ............................................................................................................................ 43

PCE* ECONOMIZER .................................................................................................................................................... 44

SPK* - SINGLE POINT WIRING KIT ........................................................................................... ................................ 45

UNIT WIRING DIAGRAMS .......................................................................................................................................... 46

IMPORT ANT INFORMA TION

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.

IMPORT ANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

This unit should not be connected to, or used in conjunction with, any devices that are not design certified for use with this unit or have not been tested and approved by Daikin. Serious property damage or personal injury, reduced unit performance and/or hazardous conditions may result from use of devices that have not been approved or certified by Daikin.

WARNING

NLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR REPAIR (HEREINAFTER MANUAL SHOULD SERVICE THE EQUIPMENT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES ASSUME RESPONSIBILITY FOR ANY INJURY OR PROPERTY DAMAGE WHICH MAY RESULT

. IN

LICENSES TO SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL, ONLY LICENSED PERSONNEL SHOULD SERVICE THE EQUIPMENT 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

, “

SERVICE

”)

THE EQUIPMENT SPECIFIED IN THIS

. THE

MANUFACTURER WILL NOT

. IF

YOU SERVICE THIS UNIT, YOU

ADDITION, IN JURISDICTIONS THAT REQUIRE ONE OR MORE

. I

MPROPER

O PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH,

DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS A PPLIANCE.

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 INFORMA TION LINE - DAIKIN BRAND PRODUCTS

TOLL FREE 1-855-770-5648 (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.)

Y our 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.

WARNING

EFRIGERANTS ARE HEAVIER THAN AIR. THEY CAN "P USH OUT" THE

OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPAC E. POSSIBL E DI FFI CULTY IN BR EAT HING O R DEA TH:

EVER PU RGE RE FRIG ERA NT INT O AN E NCLOS ED R OOM OR SPACE . BY

•

LAW, ALL REF RIGERANTS MUST BE RECLAIMED.

F AN INDOOR LEAK IS SUSPECTED, THOROUGHLY VENTILATE THE AREA

•

BEFORE BEGINNING WORK.

•

IQUI D REFRIGE RANT CAN BE VERY COLD . TO AVOID POSSIBLE FROST-

BITE OR BLINDNESS, AVOID CONTACT WITH REFRIGERANT AND WEAR GLOVES AND GOGGLES. SKI N OR E YES, S EEK M EDI CA L HELP IMME DI AT ELY .

•

ALWAYS FOLLOW EPA REGULATI ONS. NEVER BUR N REFRIGERANT,

AS POISON OUS GAS WI LL BE PRODUC ED.

F LIQUID REFRIGERANT DOES CONTACT YOUR

O AVO ID

WARNING

TO AVOID POSSIBLE EXPLOSION:

• NEVER APPLY FLAME OR S TEAM TO A REFRIGERANT CYL INDER. IF YOU MUST HEAT A CYLINDE R FOR FASTER CHARGING , PARTIALLY IMMERSE IT IN WARM WATER.

• NE VER FILL A CYLINDER MO RE THAN 80% FULL OF LIQUID R EFRIGERANT.

• NE VER ADD ANYTHING O THER THAN R-22 TO AN R-22 CYLINDER OR R-410A TO AN R-410A CYLINDER. THE SERVICE EQUIPMENT USED MUST BE LISTED OR CERTIF IED FOR THE TYPE OF REFRIGE RANT USED.

• STORE CYLINDERS IN A CO OL, DRY PLACE. NEVER USE A CYLIND ER AS A PLATFORM OR A ROLLER.

WARNING

O AVOI D P O SSIBL E E XP LOSI ON, US E ONLY R ETURN AB LE ( NOT DISPO SABL E)

SERVICE CYLINDERS WHEN REMOVING REFRIGERANT FROM A SYSTEM.

•

NSURE T HE CYL INDER I S FREE O F DAMA GE WHIC H COULD LEAD TO A

LEAK OR EXPLOSION.

•

NSURE T HE HYDR OSTATI C TEST DATE DO ES NOT E XCEE D 5 YEARS .

•

NSURE THE PRESSURE RATING MEETS OR EXCEEDS 400 LBS.

HEN I N DOUB T, DO NOT U SE CYLI ND ER.

WARNING

SYSTEM CONTAMINANT S, IMPROPER SERVICE PROCEDU RE AND/OR PHYSICAL

ABUSE AFFECTING HE RMETIC COMPRESSOR ELECTRI CAL TERMINALS MAY CAUSE DANGEROUS SYSTEM 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.

O AVOID POSSIBLE INJURY, EXPLOSION OR DEATH, PRACTICE SAFE

HANDLING OF REFRIGERANTS.

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 IDENTIFICATION

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

D P13CH244 1AA

Brand Engineer ing D - Daik in Minor revision

Product T P - Packa

SEER 1 - 208/ 230 V single phase 60 Hz 13 - 13 SEER 2 - 220/240 V single phase 50 Hz 14 - Up to 1 4 SEER 3 - 208/230 V three phase 60 Hz 15 - Up to 1 5 SEER 4 - 460 V three phas e 60 Hz

Unit Type H - Heat Pump Ref rigerant C - Air Conditioner 4 - R-410A

Confi M - Multi-position 24 - 2 to n 42 - 3.5 ton H - Horizontal 30 - 2.5 ton 48 - 4.0 ton

eEn

ed Major revision

uration Tonnage Nominal

ineering

Voltage

5 - 380/415 V three phase 50 Hz

3 6 - 3 to n 6 0 - 5 t o n

PRODUCT IDENTIFICATION

Model # Pa cka ge Cooling Description

aikin Package Cooling up to 13 Seer R410A Horizontal elec tric cooling unit.

DP13CH[24-60]41**

DP14CH[24-60]41** DP14CH24-3041BB

DP14CH3641AC

DP14CH42-6041BB DP14CH24-3041BC

DP14CH3641AD

DP14CH42-6041BC

Model # Package Heat Pump Description

DP13HH[24-60]41**

DP14HH[24-60]41**

DP14HH24-3641AC DP14HH42-6041BB

Initial release of 208-230/1/60 s ingle phase m odel s.

aikin Package Cooling up to 14 Seer R410A Horizontal elec tric cooling unit.

Initial release of 208-230/1/60 s ingle phase m odel s.

aikin Package Cooling up to 14 Seer R410A Horizontal elec tric cooling unit,

208-230/1/60 single phase models. Converted Aluminum coils with 3/8" return bends/ c ros s overs to Alum i num c oi ls us ing 9m m return bends / c ros s overs.

aikin Package Cooling up to 14 Seer R410A Horizontal elec tric cooling unit,

208-230/1/60 single phase models. Release of m odels with access box removed.

aikin Package Heat Pump up to 13 Seer R410A Horizontal heat pum p unit. Initial

releas e of 208-230/1/ 60 si ngl e phase models.

aikin Package Heat Pump up to 14 Seer R410A Horizontal heat pum p unit. Initial

releas e of 208-230/1/ 60 si ngl e phase models.

aikin Package Heat Pump up to 14 Seer R410A Horizontal heat pum p unit,

208-230/1/60 single phase models. Converted Aluminum coils with 3/8" return bends/ c ros s overs to Alum i num c oi ls us ing 9m m return bends / c ros s overs.

DP14HH24-3641AD DP14HH42-6041BC

DP14HH6041CA

aikin Package Heat Pump up to 14 Seer R410A Horizontal heat pum p unit,

208-230/1/60 single phase models. Release of m odels with access box removed.

aikin Package Heat Pump up to 14 Seer R410A Horizontal heat pum p unit, 208-230/1/60 single phase models. - Devel op and rel ease 14 SEER 5 Ton H model heat pum p wi th new 7 mm condenser c oi l.

ACCESSORIES

DP[13-14]CH/HH**41**

ACCESSORIES - DP**C/DP**H**** MODELS

Part Number Descriptio n

PCCP 101-103 14" Ro of Curb for Daik i n H - Series Package Un it A ll Chasis Requires PCP101 -103 PCP 101 -103 Downf lo w P lenu m Kit for Daik i n H - Ser i es Pac kage Units All Chassis. Requir es P CCP 1 01-103

PCP101-103R8 PCMD101-103 Manual Damper fo r D aikin H-Seri es Pac kage Units. Requi res PCP101-103

PCMDM101-103 Motorized Damper f or Daikin H- Ser ies Pac kage Units. Requires PCP 1 01- 103 GPHMD10 1- 103 Horizont al Manual Damper for Daik in H - Serie s Pac k a ge U ni t Horizontal Applications All Chassis SQRPCH101 Horizont al Squar e to Round Adapters f or H- Series Pa c kage Unit 16"&14" Round . SQRPCH102-103 Hor izontal Sq uar e t o Rou nd Adapter s f or H- Seri es Pac kage Unit 18"&14"

SQRPC101

SQRPC102-103 DPHFRA Exter na l H or izontal Filter Rack for Daikin M- and H- Series Pac k ag e Units

PCE F101-103 Elbow & Flashing w / R-8 Liner for Daiki n H- Ser i es Pa c kage Unit All Chassis CDK36 3 T on Co nc e ntric Duc t Kit CDK3651 5 3 T on Flush Mount Conc entric Duc t Kit w / Filt e r CDK3653 0 3 T on Step Down Co nc e ntric Duc t Kit CDK3653 5 3 T on St ep Do wn C oncentric D uct Kit w/ F ilter CDK4872 4 - 6 Ton Concentric Duct Kit CDK4872 515 4 - 6 To n Flush Mount Co nc e ntric Duc t Kit w / Filt er CDK4872 530 4 - 6 To n Step Down Con c en tric Duct Kit CDK4872 535 4 - 6 To n Step Down Con c en tric Duct Kit w/ Filter DDNECNJPCHHA Downflow Economizer H-S eries Package Unit. Requires PCP 10 1-103. DHZ E C NJPGCHM Economiz er H-Series Daikin Pa c kage Unit

Downf lo w P lenu m Kit for Daik i n H - Ser i es Pac kage Units w/ R-8 Insulation Lin er All C hassis. Requires PCC P 101 -103

Downf lo w S quare to Round Adapt er for H- S eries Pa c kage Unit 16" Rounds. Requires PCCP 101- 103 and P CP1 01-10 3 Downf lo w S quare to Round Adapt er for H- S eries Pa c kage Unit 18" Rounds. Requires PCCP 101- 103 and P CP1 01-10 3

THERMOSTATS

CH70T G Manual Change over CHSATG Manual Change over

CHT18-60 M anual Changeov er

CHT90-120 M anual Changeov er

CHT P 18 -6 0HD M anu al Chan ge over

CT18-60 Manual Changeover Mechanical, Nonprogrammable Cool Only

THERMOSTATS

1213401 White Manual Changeov e r 1213402 White Manual Changeov e r 1213403 White Manual Changeov e r 1213404 White Manual Changeov e r 1213406 1213407 1213408 1213410 1213411 1213412 1213431

Beige White

White White White White White

Manual/Auto Changeover

Manual Changeov e r 5 + 2 Pr o gr amming Digital 2 Heat - 2 Cool

Manual/Auto Changeover

Manual Changeov e r

Manual Changeov e r Manual/Auto Changeover Manual/Auto Changeover 7 Day Programming Digital 3 Heat - 2 Cool

Digital, Nonprogrammable 1 Heat - 1 Cool Mechanical, Nonprogrammable 1 Heat - 1 Cool Mechanical, Nonprogrammable 1 Heat - 1 Cool Mechanical, Nonprogrammable 2 Heat - 2 Cool

Digital, Nonprogrammable 2 Heat - 1 Cool

5 + 2 Pr o gr amming Digital 1 Heat - 1 Cool Nonprogr a mmable Digital 1 Hea t - 1 Cool

7 Day Programming Digital 2 Heat - 1 Cool

Nonprogr a mmable Digital 2 Hea t - 1 Cool 5 + 2 Pr o gr amming Digital 3 Heat - 2 Cool

7 Day Programming Digital 1 Heat - 1 Cool

5 + 2 Pr o gr amming Digital 2 Heat - 1 Cool Nonprogr a mmable Digital 2 Hea t - 2 Cool

7 Day Programming Digital 3 Heat - 2 Cool

ACCESSORIES

33"

DP[13-14]CH/HH**41A*

PCCP101-103 ROOF CURB

64"

59"

29 3/8"

29 3/4"

33"

28 3/4"

31"

26"

PCP101-103 DOWNFLOW PLENUM

(Use with PCCP Roof Curb)

14"

1" Flange

Roof Curb

37"

13"

25 1/2"

33"

13"

ACCESSORIES

DP[13-14]CH/HH**41A*

PCEF101-103 ELBOW AND FLASHING KIT

28"

35"

25"

33"

25"

DDNECNJPCHHA ECONOMIZER*

(DOWNFLOW APPLICATIONS)

Model Used With

DDNECNJPCHHA

H-SERIES DAI KI N PACKAGE UNIT. REQUIRES PCP10 1- 103

20 16.25 16 23.5 12.5 45.75

ACCESSORIES

DP[13-14]CH/HH**41A*

DHZECNJPGCHM ECONOMIZER*

(HORIZONTAL APPLICATIONS)

D C

SHIPPED WITH 16 X 25 X 1" FILTER AND

14.5 X 15.5 MIST ELIMINATOR INSTALLED

A B C D E F G

Shipped with 16 x 25 x 1" Filter and 14.5 x 15.5 Mist Eliminator Installed

PGEH101/102 25.25 18.125 18 16 10.375 13.75 16.125

PGEH103 35.25 18.125 18 16 15.875 18.25 16.125

ECONOMIZER ABCDEFG

DHZECNJPGCHM 25.25 18.125 18 16 10.375 13.75 16.125

PCMD101-103 DOWNFLOW MANUAL DAMPER*

PCMDM101-103 DOWNFLOW MOTORIZED DAMPER*

*USED WITH PCP101-103 DOWNFLOW PLENUM

FILTER ACCESS PANEL

10"

18"

29 3/4"

MODEL DESCRIPTION

PCMDH101-103 Manual Da mper

PCMDM101-1 03 M o torzie d Damper

ACCESSORIES

GPHMD101-103 HORIZONTAL MANUAL DAMPER WITH DUCT FLANGE

18"

17"

12"

DP[13-14]CH/HH**41A*

25 1/4"

17 1/4"

SQRPC SQUARE TO ROUND CONVERTER

(DOWNFLOW APPLICATIONS)

1" FLANGES

1 1/2

29 1/2"

29 1/4"

SQRPC101 SQRP102-103 S R

16" 18" 16" 18"

ACCESSORIES

DP[13-14]CH/HH**41A*

SQRPCH SQUARE TO ROUND CONVERTER

(HORIZONTAL APPLICATIONS)

SQUARE TO ROUND DUCT CONVERTER PANEL

SUPPLY

OUTER FLANGE

STARTER FLANGE

SQRPCH-101 SQRPCH-102 SQRPCH-103 SQRPCH102-14 SQRPCH103-14

15" 17" 17" 15" 15"

B C 17" 17" 19" 15" 15" D 22 1/2" 24 1/2" 24 1/2" 24 1/2" 24 1/2"

SUPPLY

RETURN 16" 16" 18" 14" 14"

15" 17" 17" 15" 15"

14" 16" 16" 14" 14"

BEAD

RETURN

DPHFRA EXTERNAL FILTER KIT

(HORIZONTAL APPLICATIONS)

14" x 25" x 2" FILTER

PRODUCT DESIGN

LOCATION & CLEARANCES

NOTE: To ensure proper condensate drainage, unit must be installed in a level position.

In installations where the unit is installed above ground level and not serviceable from the ground (Example: Roof Top installations) the installer must provide a service platform for the service person with rails or guards in accordance with local codes or ordinances.

48” MIN.

10"

36"

DP[13-14]CH/DP[13-14]HH**41*

WALL

UNIT

36"

NOTE: Roof overhang should be no more than 36" and provisions made to deflect the warm discharge air out from the overhang.

Minimum clearances are required to avoid air recirculation and keep the unit operating at peak efficiency.

WARNING

TO PREVENT PO SSIBLE DAMAG E, THE UNIT SHOUL D REMAIN IN AN UPRIGHT POSITION DURING ALL RIGGING AND MOVING OPERA TIONS. TO FACILIT A TE LIFTING AND M OVING IF A CRANE IS USED, PLACE THE UNIT IN AN ADEQUATE CABLE SLIDE.

Refer to Roof Curb Installation Instructions for proper curb installation. Curbing must be installed in compliance with the National Roofing Contractors Association Manual.

Lower unit carefully onto roof mounting curb. While rigging unit, center of gravity will cause condenser end to be lower than supply air end.

Roof Curb and Platform

DP[13-14]CH/DP[13-14]HH**41*

DPCH/DPHH Package Units are designed for outdoor installations only in either residential or light commercial applications.

NOTE: To ensure proper condensate drainage, unit must be installed in a level position.

The connecting ductwork (Supply and Return) can be connected for horizontal discharge airflow. In the down discharge applications, a matching Platform/Roof Curb (PCCP) and Downflow Plenum (PCP101-103) is recommended for horizontal models only.

A return air filter must be installed behind the return air grille(s) or provision must be made for a filter in an accessible location within the return air duct. The minimum filter area should not be less than those sizes listed in the Specification Section. Under no circumstances should the unit be operated without return air filters.

A 3/4" - 14 NPT drain connector is provided for removal of condensate water from the indoor coil. In order to provide proper condensate flow, do not reduce the drain line size.

Refrigerant flow control is achieved by use of restrictor orifices. These models use the FasTest Access Fitting System, with a saddle that is either soldered to the suction and liquid lines or is fastened with a locking nut to the access fitting box (core) and then screwed into the saddle. Do not remove the core

from the saddle until the refrigerant charge has been removed. Failure to do so could result in property damage or personal injury.

The single phase units use permanent split capacitors (PSC) design compressors. Starting components are therefore not required. A low MFD run capacitor assists the compressor to start and remains in the circuit during operation.

The outdoor fan motors are single phase capacitor type motors.

PRODUCT DESIGN

Air for condensing (cooling) is drawn through the outdoor coil by a propeller fan, and is discharged vertically out the top of the unit. The outdoor coil is designed for .0 static. No additional restriction (ductwork) shall be applied.

Conditioned air is drawn through the filter(s), field installed, across the evaporator coil and back into the conditioned space by the indoor blower.

COMPRESSORS

Some DPCH/DPHH series package units use the Compliant Scroll compressor, instead of traditional reciprocating compressors. Still other models use reciprocating compressors.

A scroll is an involute spiral which, when matched with a mating scroll form as shown, generates a series of crescent shaped gas pockets between the two members.

During compression, one scroll remains stationary (fixed scroll) while the other form (orbiting scroll) is allowed to orbit (but not rotate) around the first form.

NOTE: Operating pressures and amp draws may differ from standard reciprocating compressors. This information can be found in the unit's Technical Information Manual.

INDOOR BLOWER MOTOR

Some DPCH/DPHH model package units use a EEM blower motor while others use the standard PSC type blower motor. The EEM motor is a 3 Phase brushless DC (single phase AC input), ball bearing construction motor with an integral control module with an internal FCC B EMI filter.

The EEM motor is continuously powered with line voltage. The switched 24 volt control signal is controlled by the thermostat in the cooling and heat pump mode and the blower relay in the electric heat mode.

ELECTRICAL WIRING

The units are designed for operation at the voltages and hertz as shown on the rating plate. All internal wiring is complete. Ensure the power supply to the compressor contactor is brought to the unit as shown on the supplied unit wiring diagram. The 24V wiring must be connected between the unit control panel and the room thermostat.

As this motion occurs, the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume. When the pocket reaches the center of the scroll form, the gas, which is now at a high pressure, is discharged out of a port located at the center.

During compression, several pockets are being compressed simultaneously, resulting in a very smooth process. Both the suction process (outer portion of the scroll members) and the discharge process (inner portion) are continuous.

Some design characteristics of the Compliant Scroll compressor are:

• Compliant Scroll compressors are more tolerant of liquid refrigerant.

NOTE: Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant, continued floodback or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure.

• Compliant Scroll compressors use "POE" or polyolester oil, which is NOT compatible with mineral oil based lubricant like 3GS. "POE" oil must be used if additional oil is required.

• Compliant scroll compressors perform "quiet" shutdowns that allow the compressor to restart immediately without the need for a time delay. This compressor will restart even if the system has not equalized.

WARNING

TO AVOID PERSO NAL INJ UR Y OR DEA T H DUE TO ELECTRI C SHOC K, WIRING TO THE UNIT MUST BE PROPERLY POLA RIZ ED AN D GROUNDED.

WARNING

PRODUCT DESIGN

LINE VOLTAGE WIRING

Power supply to the unit must be N.E.C. Class 1, and must comply with all applicable codes. The unit must be electrically grounded in accordance with the local codes or, in their absence, with the latest edition of the National Electrical Code, ANSI/NFPA No. 70, or in Canada, Canadian Electrical Code, C22.1, Part 1. A fused disconnected must be provided and sized in accordance with the unit minimum circuit ampacity.

The best protection for the wiring is the smallest fuse or breaker which will hold the equipment on line during normal operation without nuisance trips. Such a device will provide maximum circuit protection.

All line voltage connections must be made through weather proof fittings. All exterior power supply and ground wiring must be in approved weather proof conduit. Low voltage wiring from the unit control panel to the thermostat requires coded cable.

The unit transformer is connected for 230V operation. If the unit is to operate on 208V, reconnect the transformer primary lead as shown on the unit wiring diagram.

If it is necessary for the installer to supply additional line voltage wiring to the inside of the package unit, the wiring must comply with all local codes. This wiring must have a minimum temperature rating of 105°C. All line voltage splices must be made inside the unit or heat kit control box.

SYSTEM OPERATION

COOLING

The refrigerant used in the system is R-410A. It is a clear, colorless, non-toxic and non-irritating liquid. R-410A is a 50:50 blend of R-32 and R-125. The boiling point at atmospheric pressure is -62.9°F.

A few of the important principles that make the refrigeration cycle possible are: heat always flows from a warmer to a cooler body. Under lower pressure, a refrigerant will absorb heat and vaporize at a low temperature. The vapors may be drawn off and condensed at a higher pressure and temperature to be used again.

The indoor evaporator coil functions to cool and dehumidify the air conditioned spaces through the evaporative process taking place within the coil tubes.

Heat is continually being transferred to the cool fins and tubes of the indoor evaporator coil by the warm system air. This warming process causes the refrigerant to boil. The heat removed from the air is carried off by the vapor.

As the vapor passes through the last tubes of the coil, it becomes superheated. That is, it absorbs more heat than is necessary to vaporize it. This is assurance that only dry gas will reach the compressor. Liquid reaching the compressor can weaken or break compressor valves.

The compressor increases the pressure of the gas, thus adding more heat, and discharges hot, high pressure superheated gas into the outdoor condenser coil.

In the condenser coil, the hot refrigerant gas, being warmer than the outdoor air, first loses its superheat by heat transferred from the gas through the tubes and fins of the coil. The refrigerant now becomes saturated, part liquid, part vapor and then continues to give up heat until it condenses to a liquid alone. Once the vapor is fully liquefied, it continues to give up heat which subcools the liquid, and it is ready to repeat the cycle.

COOLING CYCLE

Cooling Only Models

When the contacts of the room thermostat close, making terminals R to Y and R to G, the low voltage circuit to the contactor is completed starting the compressor and outdoor fan motor. This also energizes the indoor blower through the normally open contacts of the EBTDR on models equipped with PSC type blower motors, and through the blower relay on models equipped with EEM blower motors.

When the thermostat is satisfied, breaking the circuit between R to Y and R to G, the compressor and outdoor fan motor will stop. The indoor blower will stop after the fan off delay.

If the room thermostat fan selector switch should be set to the "on" position then the indoor blower would run continuous rather than cycling with the compressor.

Heat Pump Models

Any time the room thermostat is switched to cool, the O terminal is energized. This energizes the 24 volt coil on the reversing valve and switches it to the cooling position.

DP[13-14]CH/HH**41A*

When the contacts of the room thermostat close, this closes the circuit from R to Y and R to G in the unit.

This energizes the compressor contactor and will energize the indoor blower following the EBTDR 7 second fan on delay on models equipped with PSC type blower motors, and instantly on models equipped with EEM blower motors with the EEM motor.

When the thermostat is satisfied, it opens its contacts breaking the low voltage circuit causing the compressor contactor to open and indoor fan to stop after the EBTDR 65 second delay on models equipped with PSC type blower motors, and after the programmed 60 second off delay on models equipped with EEM blower motors with the EEM motor.

If the room thermostat fan selector switch should be set to the "on" position then the indoor blower would run continuous rather than cycling with the compressor.

HEATING CYCLE

Cooling Only Units

NOTE: The following only applies if the cooling only unit has an approved electric heat kit installed for heating. If auxiliary electric heaters should be used, they may be controlled by outdoor thermostats (OT18-60A or OT/EHR18-60A).

DPC Models with PSC Type Blower Motors

With the thermostat set to the heat position and a call for heat, R to W will be energized. This will energize the electric heat sequencers. When the normally open contacts of the heat sequencers close, this will energize the electric resistance heat and also the 240 volt coil on the isolation relay in the control panel. The normally open contacts of the isolation relay will close energizing the indoor blower motor through the normally closed contacts of the EBTDR.

When the thermostat is satisfied, this breaks the circuit from R to W. This will turn off the electric heaters, and the indoor blower after the programmed 60 second off delay on 5 ton units with the EEM motor.

DPC Models Equipped with EEM Blower Motors

With the thermostat set to the heat position and a call for heat, R to W will be energized. This will energize the electric heat sequencers and the EEM motor. The electric heat will be energized through the normally open contacts of the electric heat sequencers. The indoor blower will be energized through W from the thermostat.

When the thermostat is satisfied, this breaks the circuit from R to W. This will turn off the electric heaters, and the indoor blower after the programmed 60 second off delay .

Heat Pump Units

On a call for first stage heat, the contacts of the room thermostat close. This energizes terminals R to Y and R to G, the low voltage circuit to the contactor is completed starting the compressor and outdoor fan motor. This also energizes the indoor blower through the normally open contacts of the EBTDR after a 7 second on delay on models equipped with PSC type blower motors, and instantly on models equipped with EEM blower motors.

SYSTEM OPERATION

DP[13-14]CH/HH**41A*

When the thermostat is satisfied, breaking the circuit between R to Y and R to G, the compressor and outdoor fan motor will stop. The indoor blower will stop after the EBTDR 65 second off delay on models equipped with PSC type blower motors, and after the programmed 60 second off delay on models equipped with EEM blower motors .

When auxiliary electric heaters are used, a two stage heating single stage cooling thermostat would be installed.

Should the second stage heating contacts in the room thermostat close, which would be wired to W1 at the unit low voltage connections, this would energize the coil(s) of the electric heat relay(s). Contacts within the relay(s) will close, bringing on the electric resistance heaters.

If auxiliary electric heaters should be used, they may be controlled by outdoor thermostats (OT18-60A or OT/EHR18-60A).

Emergency Heat Mode (Heat Pumps)

NOTE: The following only applies if the unit has an approved electric heat kit installed for auxiliary heating.

DPH Models Equipped with PSC Type Blower Motors

With the thermostat set to the emergency heat position and a call for 2nd stage heat, R to W1 will be energized. This will energize the electric heat sequencers. When the normally open contacts of the heat sequencers close, this will energize the electric resistance heat and also the 240 volt coil on the isolation relay in the control panel. The normally open contacts of the isolation relay will close energizing the indoor blower motor through the normally closed contacts of the EBTDR.

DPH Models Equipped with EEM Blower Motors

With the thermostat set to the emergency heat position and a call for 2nd stage heat, R to W1 will be energized. This will energize the electric heat sequencers and the EEM The electric heat will be energized through the normally open contacts of the electric heat sequencers. The indoor blower will be energized through W from the thermostat.

motor.

DEFROST CYCLE

Package Heat Pumps

The defrosting of the outdoor coil is jointly controlled by the defrost control board and the defrost thermostat.

Solid State 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, or 90 minutes may be selected by setting the circuit board jumper to 30, 60, or 90 respectively. Accumulation of time for the timing period selected starts when the sensor closes (approximately 32 + 2° F), and when the room 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 60° 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 twelve minute override interrupts the unit’s defrost period.

FAN OPERATION

Continuous Fan Mode Models Equipped with PSC Type Blower Motors

If the thermostat calls for continuous fan, the indoor blower will be energized from the normally open contacts of the EBTDR after a 7 second delay.

Anytime there is a call for continuous fan, the indoor blower will be energized through the normally open contacts of the EBTDR, regardless of a call for heat or cool.

If the thermostat is not calling for heat or cool, and the fan switch on the thermostat is returned to the automatic position, the fan will stop after a 65 second delay.

Continuous Fan Mode Models Equipped With EEM Blower Motors

If the thermostat calls for continuous fan, the indoor blower will be energized from the G terminal of the thermostat to the EEM blower motor.

If a call for heat or cool occurs during a continuous fan call, the EEM motor will always recognize the call for the highest speed and ignore the lower speed call.

If the thermostat is not calling for heat or cool, and the fan switch on the thermostat is returned to the automatic position, the fan will stop after the programmed 60 second off delay on units with the EEM motor.

SYSTEM OPERATION

Typical Package Cooling

Indoor

Coil

Restrictor Orifice Assembly in Cooling Operation

Outdoor

Coil

Chatleff

Orifice

Assy

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

Reve rs ing Valve

(Energized)

Indoor

Coil

Accumulator

Typical Heat Pump System in Heating

Outdoor

Coil

Indoor

Coil

Reve rs ing Valve

(De-E ner gized)

Outdoor

Coil

Accumulator

SCHEDULED MAINTENANCE

The owner should be made aware of the fact, that, as with any mechanical equipment the Package Cooling and Heat Pump units require regularly scheduled maintenance to preserve high performance standards, prolong the service life of the equipment, and lessen the chances of costly failure.

In many instances the owner may be able to perform some of the maintenance; however, the advantage of a service contract, which places all maintenance in the hands of a trained serviceman, should be pointed out to the owner.

WARNING

ONCE A MONTH

1. Inspect the return filters of the evaporator unit and clean or change if necessary.

NOTE: Depending on operation conditions, it may be necessary to clean the filters more often. If permanent type filters are used, they should be washed with warm water, dried and sprayed with an adhesive according to manufacturers recommendations.

2. When operating on the cooling cycle, inspect the condensate line piping from the evaporator coil. Make sure the piping is clear for proper condensate flow.

ONCE A YEAR

Qualified Service Personnel Only

1. Clean the indoor and outdoor coils.

2. Clean the casing of the outdoor unit inside and out.

3. Motors are permanently lubricated and do not require oiling. TO AVOID PREMATURE MOTOR FAILURE, DO NOT OIL.

4. Manually rotate the outdoor fan and indoor blower to be sure they run freely.

5. Inspect the control panel wiring, compressor connections, and all other component wiring to be sure all connections are tight. Inspect wire insulation to be certain that it is good.

6. Check the contacts of the compressor contactor. If they are burned or pitted, replace the contactor.

7. Using a halide or electronic leak detector, check all piping and etc. for refrigerant leaks.

8. Check the combustion chamber (Heat Exchanger) for soot, scale, etc. Inspect all burners for lint and proper positioning.

9. Start the system, using the proper instrumentation check gas inlet and manifold pressures, burner flame and microamp signal. Adjust if necessary.

10.Start the system and run both a Cooling & Heating Performance Test. If the results of the test are not satisfactory, see the "Service Problem Analysis" Chart of the possible cause.

TEST EQUIPMENT

Proper test equipment for accurate diagnosis is as essential as regular hand tools.

The following is a must for every service technician and service shop:

1. Thermocouple type temperature meter - measure dry bulb temperature.

2. Sling psychrometer- measure relative humidity and wet bulb temperature.

3. Amprobe - measure amperage and voltage.

4. Volt-Ohm Meter - testing continuity, capacitors, and motor windings.

5. Accurate Leak Detector - testing for refrigerant leaks.

6. High Vacuum Pump - evacuation.

7. Electric Vacuum Gauge, Manifold Gauges and high vacuum hoses - to measure and obtain proper vacuum.

8. Accurate Electronic Scale - measure proper refrigerant charge.

9. Inclined Manometer - measure static pressure and pressure drop across coils.

Other recording type instruments can be essential in solving abnormal problems; however, in many instances they may be rented from local sources.

Proper equipment promotes faster, more efficient service, and accurate repairs with less call backs.

SERVICING

COOLING /HEAT PUMP- SERVICE ANALYSIS GUIDE

Complaint

POSSIBLE CA USE

DOT S IN ANALY SIS

GUIDE INDICATE

"PO S SI B L E CAUSE"

Power Fail u re Blown Fuse Unbalanced Power, 3PH Loose Connection S hor t e d or Broken Wire s Open Fan Overload Fa ulty Thermostat Fa ulty Transformer Shorte d or Open Capacitor Inter nal Com Shorte d or Grounded Compressor Compressor Stuck Fa ulty Compresso r Contactor Fa ulty Fan Contro l Open Control Circuit Low V oltage Fa ulty Evap. Fan Motor Shorte d or Grounded Fan Motor Improper Co oling Anticipator Shorta ge of Refrigerant Res t ric t ed Li quid Line Open Elemen t or Limit on Elec. Heater Dirty Air Filter Dirty Indo or Coil Not enough air across Indoor Coil Too much air across Indoor Coil Ove rcharg e of Refrigerant Dirty Outdoor Coil Non con densib les Re c i r c ulati on of Co ndens i ng Air Infiltration of Outdoor Air Improperly Located Thermostat Air Flow Unbalanced S y s tem Un de rsi z ed Broken Intern al Parts Broken Valves Inefficient Compressor Loose Hold-down Bolts Fa ulty Reversing Valve Faulty Defrost Control Faulty Defrost Thermostat Flowrator Not Seating P roperly

ressor Overload Open

Unit will not defrost

System Operating Pressures

Low suct ion pressure

Lo w head pr ess u r e

High suctio n pressure

No Cooling Unsatisfactory Cooling/Hea ti ng

SYMPTOM

System will not start

Compressor will not s t art - fan r uns

Comp. and Cond. Fan will not start

Evaporator fan will not start

Condenser fan will not s tart

Compressor runs - goes of f on overload

Compressor cycles o n overload

Syste m ru ns continuous ly - little co oling/htg

Too cool and then too warm

Not cool enou gh on warm day s

Certain areas to o cool, others too warm

Co mpress or is noisy

System runs - blows cold air in heating

Unit w ill not terminate defrost

•

•••

••••••

••

••• •

••

•••••

•

••

•••

♦ T est Cont in ui t

♦ Use Test Cord S-17 D

•••

•

•••

••

•• •• •

♦♦

♦

••

••• •

•• •

•

•• •

••

♦

•

••

♦

•• •

•••

••

•• ••

•

♦

•

♦

•

♦♦ ♦ ♦ ♦♦ ♦♦ ♦♦♦ ♦

♦♦♦♦♦♦♦

••

•••

Cooling or Heatin g Cycle (Heat Pump) H eating Cycle Only (Heat Pump)

•

♦

Test Method

Remedy

See Service Procedure Ref.

Hi gh he ad pr es s u re

Test Vo lt age S-1 Inspect Fuse Size & Type S-1 Test Vo lt age S-1 Inspect Connection - Tight en S-2, S -3 Test Circuits With Ohmmeter S-2, S -3 Test Cont in ui ty of Over l oa d S- 17 Test con tinu ity of Thermostat & Wirin Check control cir cuit wi th volt mete r S-4 Test Capacitor S-15

Test Motor WindingsS-17B

Test con tinu ity of Coil & Contacts S-7, S -8 Test con tinu ity of Coil And Cont acts S-7, S-9 Test Control Circuit with Voltmeter S-4 Test Vo lt age S-1

♦ Repair or Replace S -16

Test Motor Windings S-16A,D Check resistance of Anticipator S-3B Test For Leaks, Add Refrigerant S-101,103 Remove Restriction, Replace Restri cted Part S-11 2 Test Heat er Ele m ent and Cont ro ls S- 26 ,S -2 7 Inspect Filter-Cle an or Replace

♦

Inspect Coil - Clean

♦ ♦ Chec k Bl owe r S

Reduce Bl ow er Speed S-200 Recove r Pa rt of Charge S-113 Inspect Coil - Cle an

•

Re c ov e r Ch a rge, Evacuate, Recharge S -114

•

Remove Obstruction to Air Flow Check Wi ndows, Doors, Ve nt Fans , Etc. Rel oca t e Ther m os t at Read j ust Ai r Vo lu m e D a m per s Refigur e Cooli ng Load Replace Compresso r S-115 Test Compressor Efficie nc Test Com pr ess o r Ef fi ci enc y S - 104 Tighten Bolts Replace Valve or Solenoid S-21, 122 Test Cont ro l S- 24 Test Defrost Thermostat S-25 Check Flowrator & Seat or Replace Flowrator S-111

of Over l oa d S- 17

eed, Duct Static Press, Filter S-200

S-3

S-104

SERVICING

S-1 CHECKING VOLTAGE

S-2 CHECKING WIRING

WARNING

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

With power ON:

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. 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 Volta ge

Voltage Min. Max.

460 437 506

208/230 198 253

WARNING

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

S-3A THERMOSTAT AND WIRING

With power ON and thermostat calling for cooling.

1. Use a voltmeter to verify 24 volts present at thermostat wires C and R.

2. If no voltage present, check transformer and transformer wiring. If 24 volts present, proceed to step 3.

3. Use a voltmeter to check for 24 volts at thermostat wires C and Y.

4. No voltage indicates trouble in the thermostat, wiring or external transformer source.

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

Indoor Blower Motor

With power ON:

1. Use a voltmeter to verify 24 volts present at thermostat wires C and R.

2. If no voltage present, check transformer and transformer wiring. If 24 volts present, proceed to step 3.

SERVICING

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

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

5. No voltage, indicates the trouble is in the thermostat or wiring.

6. 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.

WARNING

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

With power ON:

S-3C HEATING ANTICIPATOR

The heating anticipator is a wire-wound adjustable heater, which is energized during the "ON" cycle to help prevent overheating of the conditioned space.

The anticipator is a part of the thermostat and if it should fail for any reason, the thermostat must be replaced. See the following for recommended heater anticipator setting.

To determine the proper setting, use an amp meter to measure the amperage on the "W" wire going to the thermostat.

Use an amprobe as shown below. Wrap 10 turns of thermostat wire around the stationary jaw of the amprobe and divide the reading by 10.

10 TURNS OF THERMOSTAT WIRE (From "W" on thermostat )

STATIONARY JAW OF AMPROBE

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 is present at the primary voltage side of the

transformer and 24 volts is not present on the secondary side, then the transformer is inoperative. Replace.

S-7 CHECKING CONTACTOR AND/OR RELAYS

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 deenergized, springs return the contacts to their normal position.

WARNING

DISCONNECT POWER SUPPLY BEFORE SERVICING.

READS 4 AMPS CURRENT DRAW WOULD BE .4 AMPS

Checking Heat Anticipator Amp Draw

S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT

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

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

WARNING

DISCONNECT POWER SUPPLY BEFORE SERV ICING.

SERVICING

SINGLE PHASE

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

(Single Phase)

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

main power supply. If voltage present, proceed to step B.

B. T1 to T2 - Meter should read the same as L1 to L2 in

step A. If voltage readings are not the same as step A, replace contactor.

L1L2

3. If not as in steps 1 and 2, replace EBTDR.

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.

PSC Type Blower Motor Models Only

Heat pump and cooler models equipped with PSC type blower motors have an isolation relay with a 240 volt holding coil in

addition to the EBTDR.

WARNING

DISCONNE CT PO WER SUPP LY BE FORE SE RV ICIN G.

Turn power off.

S-9 CHECKING FAN RELAY CONTACTS

The Electronic Blower Time Delay Relay is used on models equipped with PSC type blower motors.

WARNING

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.

Testing relay holding coil

1. Remove the leads from the holding coil terminals 1 and 3.

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 POWER SUPPLY BEFORE SERVICING.

Turn power off.

1. Using a VOM, test resistance across relay terminals 2 and

4. Should read open.

2. Turn power on.

SERVICING

With power ON:

WARNING

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. In no voltage, check wiring from heater kit to relay. 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.

S-11 CHECKING LOSS OF CHARGE PROTECTOR

(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 + 7 PSIG. It will automatically cut-in (close) at approximately 50 + 7 PSIG.

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

S-12 CHECKING HIGH PRESSURE CONTROL

LINE V OLTAGE N OW PRES E NT.

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.

If it cuts-out at 610 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.

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.

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

The high pressure control senses the pressure in the liquid 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.

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.

SERVICING

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

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 will 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).

S-15B CAPACITANCE CHECK

WARNING

DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING.

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

Capacitance (MFD) = 2650 X Amperage

Voltage

WARNING

1. Discharge capacitor and remove wire leads.

WARNING

DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING.

Volt / Ohm Meter

VOLTMETER

15 AM P

FUSE

AMMETER

CAPACITOR

TESTING CAPACITANCE

acitor

TESTING CAPACITOR RESISTANCE

SERVICING

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

WINDINGS (PSC MOTORS)

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.

WARNING

High Voltage Connections

3/16"

LGN

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 an unpainted end of 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 any 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 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.

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 ELECT RICAL SHORT BE TWEEN THE TERMINAL AND THE COMPRESSOR HOUSING, THE TERMINAL MAY BE EXPELLED, VENTING THE VAPOR AND LIQUID CONTENTS OF THE COMPRESSOR HOUSING AND SYSTEM.

If the compressor terminal PROTECTIVE COVER and gasket (if required) is 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.

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

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.

If the following test indicates shorted, grounded or open windings, see procedure S-19 for the next steps to be taken.

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. The three phase internal overload will open all three legs.

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.

WARNING

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.

With the terminal protective cover in place, it is acceptable to replace the fuse or reset the circuit breaker ONE TIME ONLY to see if it was just a nuisance opening. If it opens again, DO NOT continue to reset.

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.

1. Remove the leads from the compressor terminals.

WARNING

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.

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.

HI-POT

COMPRESSOR GROUND TEST

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 volt-ohmmeter.

SERVICING

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.

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:

WARNING

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.

4. With power ON, close the switch.

WARNING

LINE VOLTAG E 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.

The condition of the scroll flanks is checked in the following manner.

and the charge is correct, test the reversing valve if equipped (heat pump models only. See-S-21). If the reversing valves test good, the compressor is faulty - replace the compressor.

S-18 TESTING CRANKCASE HEATER

(OPTIONAL ITEM)

Note: Not all compressors use crankcase heaters.

The crankcase heater must be energized a minimum of twentyfour (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 POWER SUPPLY BEFORE SERVICING.

1. Disconnect the heater lead wires.

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

S-18A CHECKING CRANKCASE HEATER THERMOSTAT

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.

1. Attach gauges to the high and low side of the system.

2. Start the system and run a “Cooling Performance Test.

If the test shows:

a. Below normal high side pressure. b. Above normal low side pressure. c. Low temperature difference across coil. d. Low amp draw at compressor.

S-21 CHECKING REVERSING VALVE AND SOLENOID

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.

SERVICING

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.

S-24 TESTING DEFROST CONTROL

NOTE: PCBDM133 defrost controls have a three (3) minute compressor off cycle delay.

NOTE: The PCBDM133 defrost controls are shipped from the

factory with the compressor delay option selected. This will de-energize the compressor contactor for 30 seconds on defrost initiation and defrost termination. If the jumper is set to Normal, the compressor will continue to run during defrost initiation and defrost termination. The control will also ignore the low pressure switch connected to R-PS1 and PS2 for 5 minutes

upon defrost initiation and 5 minutes after defrost termination. 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" ("R-DFT" on PCBDM133) 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.

5. Using VOM check for voltage across terminals "C & O" ("O-RV" on PCBDM133). 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" (W on PCBDM133) & "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. It should close at approximately 32°F ± 2°F.

3. Check the temperature at which the control opens its contacts by raising the temperature of the control. It should open at approximately 60°F.

4. If not as above, replace control.

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 ELECTRICAL POWER SUPPLY.

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-52 CHECKING HEATER ELEMENTS

Optional electric heaters may be added, in the quantities shown in the spec sheet for each model unit, to provide electric resistance heating. Under no condition shall more heaters than the quantity shown be installed.

WARNING

1. Disassemble and remove the heating element(s).

2. Visually inspect the heater assembly for any breaks in the wire or broken insulators.

3. Using an ohmmeter, test the element for continuity - no reading indicates the element is open. Replace as necessary.

SERVICING

S-100 REFRIGERATION REPAIR PRACTICE

DANGER

ALWAYS REMOVE THE REFRIGERANT CHARGE IN A PROPER MANNER BEFORE APPLYING HEAT TO THE SYSTEM.

These models use the FasTest Access Fitting System, with a saddle that is either soldered to the suction and liquid lines or is fastened with a locking nut to the access fitting box (core) and then screwed into the saddle. Do not remove the core

from the saddle until the refrigerant charge has been removed. Failure to do so could result in property damage or personal injury.

When installing a new core or reinstalling the core after removal, it is very important to note that before inserting the core into the saddle, the core and saddle must be free of debris and the “O” Ring to it. The oil is to prevent the “O” Ring from being deformed when the core is tightened completely. The core should be torqued to 8 ft. lb.

When repairing the refrigeration system:

DISC ONN EC T EL EC T RICAL POWER SU PPLY.

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.

At any time the system has been open for repair, the factory installed liquid line filter drier must be replaced.

must have a thin coating of refrigerant oil applied

WARNING

S-101 LEAK TESTING

(NITROGEN OR NITROGEN-TRACED)

WARNING

Pressure test the system using dry nitrogen and soapy water to locate leaks. If you wish to use a leak detector, charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure, then apply the detector to suspect areas. If leaks are found, repair them. After repair, repeat the pressure test. If no leaks exist, proceed to system evacuation.

For a system that contains a refrigerant charge and is suspected of having a leak, stop the operation and hold the exploring tube of the detector as close to the tube as possible, check all piping and fittings. If a leak is detected, do not attempt to apply more brazing to the joint. Remove and capture the charge, unbraze the joint, clean and rebraze.

For a system that has been newly repaired and does not contain a charge, connect a cylinder of refrigerant, through a gauge manifold, to the liquid and suction line dill valves and/or liquid line dill valve and compressor process tube.

NOTE: Refrigerant hoses must be equipped with dill valve depressors or special adaptor used. Open the valve on the cylinder and manifold and allow the pressure to build up within the system. Check for and handle leaks, as described above. After the test has been completed, remove and capture the leak test refrigerant.

S-102 EVACUATION

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.

WARNING

SERVICING

This is the most important part of the entire service procedure. The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air (non-condensable) and moisture from the system.

Air in a system causes high condensing temperature and pressure, resulting in increased power input and reduced performance.

Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids. These attack motor windings and parts, causing breakdown.

The equipment required to thoroughly evacuate the system is a high vacuum pump, capable of producing a vacuum equivalent to 25 microns absolute and a thermocouple vacuum gauge to give a true reading of the vacuum in the system.

NOTE: Never use the system compressor as a vacuum pump or run when under a high vacuum. Motor damage could occur.

WARNING

SCROLL COMPRESSORS DO NOT FRONT SEAT T HE SERVICE VALV E(S) WITH THE COMPRESSOR OPERATING IN AN ATTEMPT TO SAVE REFRIGERANT. WITH THE SUCTION LINE OF THE COMPRESSOR CLOSED OR SEVERLY RESTRICTED, THE SCROLL COMPRESSOR WILL DRAW A DEEP VACUUM VERY QUICKLY. THIS VACUUM CAN CAUSE INTERNAL ARCING OF THE FUSITE RESULTING IN A DAMAGED OR FAILED COMPRESSOR.

2. Start the vacuum pump and open the shut off valve to the high vacuum gauge manifold only. After the compound gauge (low side) has dropped to approximately 29 inches of vacuum, open the valve to the vacuum thermocouple gauge. See that the vacuum pump will blank-off to a maximum of 25 microns. A high vacuum pump can only produce a good vacuum if its oil is non-contaminated.

3. If the vacuum pump is working properly, close the valve to the vacuum thermocouple gauge and open the high and low side valves to the high vacuum manifold set. With the valve on the charging cylinder closed, open the manifold valve to the cylinder.

4. Evacuate the system to at least 29 inches gauge before opening valve to thermocouple vacuum gauge.

5. Continue to evacuate to a minimum of 250 microns. Close valve to vacuum pump and watch rate of rise. If vacuum does not rise above 1500 microns in three to five minutes, system can be considered properly evacuated.

6. If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns, moisture and non-condensables are still present. If gauge continues to rise a leak is present. Repair and re-evacuate.

7. Close valve to thermocouple vacuum gauge and vacuum pump. Shut off pump and prepare to charge.

S-103 CHARGING

WARNINGWARNING

LOW SIDE

GAUGE

AND VAL V E

1. Connect the vacuum pump, vacuum tight manifold set with high vacuum hoses, thermocouple vacuum gauge and charging cylinder as shown.

HIGH SIDE

GAUGE

AND VALVE

CAUTION

Charge the system with the exact amount of refrigerant. Refer to the specification section or check the unit nameplates

for the correct refrigerant charge. After completing airflow measurements and adjustments, the

unit’s refrigerant charge must be checked. The unit comes factory charged, but this charge is based on 400 CFM per ton at minimum ESP per AHRI test conditions (generally between .15 - .25 ESP). When air quantity or ESP is different than above, charge must be adjusted to the proper amount.

SERVICING

All package units are charged to the superheat method at the compressor suction line (these are fixed orifice devices).

For charging in the warmer months, 100F superheat at the compressor is required at conditions: 950F outdoor ambient (dry bulb temperature), 800F dry bulb / 670F wet bulb indoor ambient, approximately 50% humidity. This superheat varies when conditions vary from the conditions described.

A superheat charge chart is available for other operating conditions. Use it to provide the correct superheat at the conditions the unit is being charged at.

After superheat is adjusted it is recommended to check unit sub-cooling at the condenser coil liquid line out. In most operating conditions 12 + 40F of sub-cooling is adequate.

An inaccurately charged system will cause future problems.

1. Using a quality set of charging scales, weigh the proper amount of refrigerant for the system. Allow liquid refrigerant only to enter the high side.

2. After the system will take all it will take, close the valve on the high side of the charging manifold.

3. Start the system and charge the balance of the refrigerant through the low side.

NOTE: R410A should be drawn out of the storage container or drum in liquid form due to its fractionation properties, but should be "Flashed" to its gas state before entering the system. There are commercially available restriction devices that fit into the system charging hose set to accomplish this. DO NOT charge liquid R410A into the compressor.

4. With the system still running, close the valve on the charging cylinder. At this time, you may still have some liquid refrigerant in the charging cylinder hose and will definitely have liquid in the liquid hose. Slowly open the high side manifold valve and transfer the liquid refrigerant from the liquid line hose and charging cylinder hose into the suction service valve port. CAREFUL: Watch so that liquid refrigerant does not enter the compressor.

Final Charge Adjustment

The outdoor temperature must be 60°F or higher. Set the room thermostat to COOL, fan switch to AUTO, and set the temperature control well below room temperature.

After system has stabilized per start-up instructions, compare the operating pressures and outdoor unit amp draw to the numbers listed in the technical manual. If pressures and amp draw are too low, add charge. If pressures and amp draw are too high, remove charge. Check subcooling and superheat as detailed in the following section.

5. With the system still running, remove hose and reinstall both access fitting caps.

6. Check system for leaks.

Due to their design, Scroll compressors are inherently more tolerant of liquid refrigerant.

ING COMPRESSOR EFFICIENCY. The reason for compressor inefficiency is broken or dam-

aged suction and/or discharge valves, or scroll flanks on Scroll compressors, reducing the ability of the compressor to pump refrigerant vapor.

The condition of the valves or scroll flanks is checked in the following manner.

1. Attach gauges to the high and low side of the system.

2. Start the system and run a Cooling Performance Test. If the test shows-

⇒ Below normal high side pressure. ⇒ Above normal low side pressure. ⇒ Low temperature difference across coil. ⇒ Low amp draw at compressor.

-and the charge is correct. The compressor is faulty - replace the compressor.

S-104 CHECKING COMPRESSOR EFFICIENCY

The reason for compressor inefficiency is broken or damaged suction and/or discharge valves, or scroll flanks on Scroll compressors, reducing the ability of the compressor to pump refrigerant vapor.

During the "OFF" cycle, the high side pressure bleeds to the low side through the fixed orifice restriction device. Check equalization time as follows:

1. Attach a gauge manifold to the suction and liquid line access fittings.

2. Start the system and allow the pressures to stabilize.

3. Stop the system and check the time it takes for the high and low pressure gauge readings to equalize.

If it takes more than seven (7) minutes to equalize, the restrictor device is inoperative. Replace, install a liquid line drier, evacuate and recharge.

S-108 SUPERHEAT

CHECKING SUPERHEAT

Refrigerant gas is considered superheated whenever its temperature is higher than the saturation temperature corresponding to its pressure. The degree of superheat equals the degrees of temperature increase above the saturation temperature at existing pressure. See Temperature - Pressure Chart.

SERVICING

CAUTION

To prevent personal injury, carefully connect and disconnect manifold gauge hoses. Escaping liquid refrigerant can cause burns. Do not vent refrigerant to atmosphere. Recover during system repair or final unit disposal.

1. Run system at least 10 minutes to allow pressure to stabilize.

2. Temporarily install thermometer on suction (large) line near compressor with adequate contact and insulate for best possible reading.

3. Refer to the superheat table provided for proper system superheat. Add charge to lower superheat or recover charge to raise superheat.

Superheat Formula = Suct. Line Temp. - Sat. Suct. Temp.

Ambient Condenser

Inlet Temp (°F

Drybulb)

100

95 90 85 80 75 10 13 17 25 29 70 10 17 20 28 32 65 13 19 26 32 35 60 17 25 30 33 37

EXAMPLE:

a. Suction Pressure = 143 b. Corresponding Temp. °F. = 50 c. Thermometer on Suction Line = 59°F.

To obtain the degrees temperature of superheat, subtract 50.0 from 59.0°F.

The difference is 9° Superheat. The 9° Superheat would fall in the ± range of allowable superheat.

S-109 CHECKING SUBCOOLING

Refrigerant liquid is considered subcooled when its temperature is lower than the saturation temperature corresponding to its pressure. The degree of subcooling equals the degrees of temperature decrease below the saturation temperature at the existing pressure.

1. Attach an accurate thermometer or preferably a thermocouple type temperature tester to the liquid line close to the pressure switch.

2. Install a high side pressure gauge on the liquid access fitting.

3. Record the gauge pressure and the temperature of the line.

4. Compare the hi-pressure reading to the "Required Liquid

Return Air Temp. (°F Drybulb)

65 70 75

10 13 17 20

10 15 21 26

80 85 10 10

10 10 10 12 15 18

Line Temperature" chart. Find the hi-pressure value on the left column. Follow that line right to the column under the design subcooling value. Where the two intersect is the required liquid line temperature.

Alternately you can convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Temperature - Pressure Chart and reading to the left, find the temperature in the °F. Column.

5. The difference between the thermometer reading and pressure to temperature conversion is the amount of subcooling.

Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp.

EXAMPLE:

a. Liquid Line Pressure = 417 b. Corresponding Temp. °F. = 120° c. Thermometer on Liquid line = 109°F.

To obtain the amount of subcooling, subtract 109°F from 120°F. The difference is 11° subcooling. See the specification sheet

or technical information manual for the design subcooling range for your unit.

See R410A Pressure vs. Temperature chart.

S-111 FIXED ORIFICE RESTRICTION DEVICES

The fixed orifice restriction device (flowrator) used in conjunction with the indoor coil is a predetermined bore (I.D.).

It is designed to control the rate of liquid refrigerant flow into an evaporator coil.

The amount of refrigerant that flows through the fixed orifice restriction device is regulated by the pressure difference between the high and low sides of the system.

In the cooling cycle when the outdoor air temperature rises, the high side condensing pressure rises. At the same time, the cooling load on the indoor coil increases, causing the low side pressure to rise, but at a slower rate.

Since the high side pressure rises faster when the temperature increases, more refrigerant flows to the evaporator, increasing the cooling capacity of the system.

When the outdoor temperature falls, the reverse takes place. The condensing pressure falls, and the cooling loads on the indoor coil decreases, causing less refrigerant flow.

If a restriction should become evident, proceed as follows:

1. Recover refrigerant charge.

2. Remove the orifice assembly and clean or replace.

3. Replace liquid line drier, evacuate and recharge.

SERVICING

CHECKING EQUALIZATION TIME

During the "OFF" cycle, the high side pressure bleeds to the low side through the fixed orifice restriction device. Check equalization time as follows:

1. Attach a gauge manifold to the suction and liquid line dill valves

2. Start the system and allow the pressures to stabilize.

3. Stop the system and check the time it takes for the high and low pressure gauge readings to equalize.

If it takes more than seven (7) minutes to equalize, the restriction device is inoperative. Replace, install a liquid line drier, evacuate and recharge.

S-112 CHECKING RESTRICTED LIQUID LINE

When the system is operating, the liquid line is warm to the touch. If the liquid line is restricted, a definite temperature drop will be noticed at the point of restriction. In severe cases, frost will form at the restriction and extend down the line in the direction of the flow.

Discharge and suction pressures will be low, giving the appearance of an undercharged unit. However, the unit will have normal to high subcooling.

If a restriction is located, replace the restricted part, replace drier, evacuate and recharge.

There are other causes for high head pressure which may be found in the "Service Problem Analysis Guide."

If other causes check out normal, an overcharge or a system containing non-condensables would be indicated.

If this system is observed:

1. Start the system.

2. Remove and capture small quantities of refrigerant as from the suction line access fitting until the head pressure is reduced to normal.

3. Observe the system while running a cooling performance test. If a shortage of refrigerant is indicated, then the system contains non-condensables.

S-114 NON-CONDENSABLES

If non-condensables are suspected, shut down the system and allow the pressures to equalize. Wait at least 15 minutes. Compare the pressure to the temperature of the coldest coil since this is where most of the refrigerant will be. If the pressure indicates a higher temperature than that of the coil temperature, non-condensables are present.

Non-condensables are removed from the system by first removing the refrigerant charge, replacing and/or installing liquid line drier, evacuating and recharging.

S-113 REFRIGERANT OVERCHARGE

An overcharge of refrigerant is normally indicated by an excessively high head pressure.

An evaporator coil, using an expansion valve metering device, will basically modulate and control a flooded evaporator and prevent liquid refrigerant from returning to the compressor.

An evaporator coil, using a fixed orifice restrictor device (flowrator) metering device, could allow liquid refrigerant to return to the compressor under extreme overcharge conditions.

Also with a fixed orifice restrictor device (flowrator) metering device, extreme cases of insufficient indoor air can cause icing of the indoor coil and liquid refrigerant to return to the compressor, but the head pressure would be lower.

SERVICING

PSIG

100 102 104 106 108 110 112

°F 12 14 16 18 20 22 24 26 28 -17.9 130.0 44.7 232.0 78.9 334.0 103.7 436.0 123.5 538.0 140.1 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 7.3 160.0 56.2 262.0 86.9 364.0 110.0 466.0 128.7 596.0 148.4 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 25.4 190.0 66.4 292.0 94.3 394.0 115.8 496.0 133.6 656.0 156.6 90 92 94 96 98

-37.7

-34.7

-32.0

-29.4

-36.9

-24.5

-22.2

-20.0

-15.8

-13.8

-11.9

-10.1

-8.3

-6.5

-4.5

-3.2

-1.6

0.0

1.5

3.0

4.5

5.9

8.6

10.0

11.3

12.6

13.8

15.1

16.3

17.5

18.7

19.8

21.0

22.1

23.2

24.3

26.4

27.4

28.5

29.5

30.5

31.2

32.2

33.2

34.1

35.1

35.5

36.9

PSIG

114.0

116.0

118.0

120.0

122.0

124.0

126.0

128.0

132.0

134.0

136.0

138.0

140.0

142.0

144.0

146.0

148.0

150.0

152.0

154.0

156.0

158.0

162.0

164.0

166.0

168.0

170.0

172.0

174.0

176.0

178.0

180.0

182.0

184.0

186.0

188.0

192.0

194.0

196.0

198.0

200.0

202.0

204.0

206.0

208.0

210.0

212.0

214.0

Pressure vs. Temperature Chart

R-410A

°F

37.8

38.7

39.5

40.5

41.3

42.2

43.0

43.8

45.5

46.3

47.1

47.9

48.7

49.5

50.3

51.1

51.8

52.5

53.3

54.0

54.8

55.5

57.0

57.7

58.4

59.0

59.8

60.5

61.1

61.8

62.5

63.1

63.8

64.5

65.1

65.8

67.0

67.7

68.3

68.9

69.5

70.1

70.7

71.4

72.0

72.6

73.2

73.8

PSIG

216.0

218.0

220.0

222.0

224.0

226.0

228.0

230.0

234.0

236.0

238.0

240.0

242.0

244.0

246.0

248.0

250.0

252.0

254.0

256.0

258.0

260.0

264.0

266.0

268.0

270.0

272.0

274.0

276.0

278.0

280.0

282.0

284.0

286.0

288.0

290.0

294.0

296.0

298.0

300.0

302.0

304.0

306.0

308.0

310.0

312.0

314.0

316.0

°F

74.3

74.9

75.5

76.1

76.7

77.2

77.8

78.4

79.5

80.0

80.6

81.1

81.6

82.2

82.7

83.3

83.8

84.3

84.8

85.4

85.9

86.4

87.4

87.9

88.4

88.9

89.4

89.9

90.4

90.9

91.4

91.9

92.4

92.8

93.3

93.8

94.8

95.2

95.7

96.2

96.6

97.1

97.5

98.0

98.4

98.9

99.3

99.7

PSIG

318.0

320.0

322.0

324.0

326.0

328.0

330.0

332.0

336.0

338.0

340.0

342.0

344.0

346.0

348.0

350.0

352.0

354.0

356.0

358.0

360.0

362.0

366.0

368.0

370.0

372.0

374.0

376.0

378.0

380.0

382.0

384.0

386.0

388.0

390.0

392.0

396.0

398.0

400.0

402.0

404.0

406.0

408.0

410.0

412.0

414.0

416.0

418.0

°F

100.2

100.7

101.1

101.6

102.0

102.4

102.9

103.3

104.2

104.6

105.1

105.4

105.8

106.3

106.6

107.1

107.5

107.9

108.3

108.8

109.2

109.6

110.4

110.8

111.2

111.6

112.0

112.4

112.6

113.1

113.5

113.9

114.3

114.7

115.0

115.5

116.2

116.6

117.0

117.3

117.7

118.1

118.5

118.8

119.2

119.6

119.9

120.3

PSIG

420.0

422.0

424.0

426.0

428.0

430.0

432.0

434.0

438.0

440.0

442.0

444.0

446.0

448.0

450.0

452.0

454.0

456.0

458.0

460.0

462.0

464.0

468.0

470.0

472.0

474.0

476.0

478.0

480.0

482.0

484.0

486.0

488.0

490.0

492.0

494.0

498.0

500.0

502.0

504.0

506.0

508.0

510.0

512.0

514.0

516.0

518.0

520.0

°F

120.7

121.0

121.4

121.7

122.1

122.5

122.8

123.2

123.9

124.2

124.6

124.9

125.3

125.6

126.0

126.3

126.6

127.0

127.3

127.7

128.0

128.3

129.0

129.3

129.7

130.0

130.3

130.7

131.0

131.3

131.6

132.0

132.3

132.6

132.9

133.3

133.9

134.0

134.5

134.8

135.2

135.5

135.8

136.1

136.4

136.7

137.0

137.3

PSIG

522.0

524.0

526.0

528.0

530.0

532.0

534.0

536.0

540.0

544.0

548.0

552.0

556.0

560.0

564.0

568.0

572.0

576.0

580.0

584.0

588.0

592.0

600.0

604.0

608.0

612.0

616.0

620.0

624.0

628.0

632.0

636.0

640.0

644.0

648.0

652.0

660.0

664.0

668.0

672.0

676.0

680.0

684.0

688.0

692.0

696.0

°F

137.6

137.9

138.3

138.6

138.9

139.2

139.5

139.8

140.4

141.0

141.6

142.1

142.7

143.3

143.9

144.5

145.0

145.6

146.2

146.7

147.3

147.9

149.0

149.5

150.1

150.6

151.2

151.7

152.3

152.8

153.4

153.9

154.5

155.0

155.5

156.1

157.1

157.7

158.2

158.7

159.2

159.8

160.3

160.8

161.3

161.8

*Based on ALLIED SIGNAL Data

SERVICING

LIQUID PRESSURE

LIQUID PR ESSU R E

AT ACCESS FITTING (PSIG)

AT SERVICE VALVE (P SIG) 8 10 12 14 16 18

REQUIRED LIQUID LINE TEMPERATURE

REQUIRED SUBCOOLING TEMPERATURE (°F)

189 58 56 54 52 50 48 195 605856545250 202 626058565452 208 646260585654 215 666462605856 222 686664626058 229 706866646260 236 727068666462 243 747270686664 251 767472706866 259 787674727068 266 807876747270 274 828078767472 283 848280787674 291 868482807876 299 888684828078 308 908886848280 317 929088868482 326 949290888684 335 969492908886 345 989694929088 354 100 98 96 94 92 90 364 102 100 98 96 94 92 374 104 102 100 98 96 94 384 106 104 102 100 98 96 395 108 106 104 102 100 98 406 110 108 106 104 102 100 416 112 110 108 106 104 102 427 114 112 110 108 106 104 439 116 114 112 110 108 106 450 118 116 114 112 110 108 462 120 118 116 114 112 110 474 122 120 118 116 114 112 486 124 122 120 118 116 114 499 126 124 122 120 118 116 511 128 126 124 122 120 118

SERVICING

S-115 COMPRESSOR BURNOUT

When a compressor burns out, high temperature develops causing the refrigerant, oil and motor insulation to decompose forming acids and sludge.

If a compressor is suspected of being burned-out, attach a refrigerant hose to the liquid line dill valve and properly remove and dispose of the refrigerant.

NOTICE

Now determine if a burn out has actually occurred. Confirm by analyzing an oil sample using a Sporlan Acid Test Kit, AK-3 or its equivalent.

Remove the compressor and obtain an oil sample from the suction stub. If the oil is not acidic, either a burnout has not occurred or the burnout is so mild that a complete clean-up is not necessary.

If acid level is unacceptable, the system must be cleaned by using the clean-up drier method.

CAUTION

DO NOT ALLOW THE SLUDGE OR OIL TO CONTACT THE SKIN, SEVERE BURNS MAY RESULT.

NOTE: Daikin does NOT approve the flushing method using R-11 refrigerant.

Suction Line Drier Clean-Up Method

The POE oils used with R410A refrigerant is an excellent solvent. In the case of a burnout, the POE oils will remove any burnout residue left in the system. If not captured by the refrigerant filter, they will collect in the compressor or other system components, causing a failure of the replacement compressor and/or spread contaminants throughout the system, damaging additional components.

Install a suction line filter drier. This drier should be installed as close to the compressor suction fitting as possible. The filter must be accessible and be rechecked for a pressure drop after the system has operated for a time. It may be necessary to use new tubing and form as required.

NOTE: At least twelve (12) inches of the suction line immediately out of the compressor stub must be discarded due to burned residue and contaminates.

1. Remove the liquid line drier and expansion valve.

2. Purge all remaining components with dry nitrogen or carbon dioxide until clean.

3 Install new components including liquid line drier.

4. Braze all joints, leak test, evacuate, and recharge system.

5. Start up the unit and record the pressure drop across the drier.

6. Continue to run the system for a minimum of twelve (12) hours and recheck the pressure drop across the drier. Pressure drop should not exceed 6 PSIG.

7. Continue to run the system for several days, repeatedly checking pressure drop across the suction line drier. If the pressure drop never exceeds the 6 PSIG, the drier has trapped the contaminants. Remove the suction line drier from the system.

8. If the pressure drop becomes greater, then it must be replaced and steps 5 through 9 repeated until it does not exceed 6 PSIG.

NOTICE: Regardless, the cause for burnout must be determined and corrected before the new compressor is started.

S-122 REVERSING VALVE REPLACEMENT

Remove the refrigerant charge from the system. When brazing a reversing valve into the system, it is of ex-

treme importance that the temperature of the valve does not exceed 250°F at any time.

Wrap the reversing valve with a large rag saturated with water. "Re-wet" the rag and thoroughly cool the valve after each brazing operation of the four joints involved. The wet rag around the reversing valve will eliminate conduction of heat to the valve body when brazing the line connection.

The use of a wet rag sometimes can be a nuisance. There are commercial grades of heat absorbing paste that may be substituted.

After the valve has been installed, leak test, evacuate and recharge.

SERVICING

S-200 CHECKING EXTERNAL STATIC PRESSURE

The minimum and maximum allowable duct static pressure is found in the Technical Information Manual.

Too great of an external static pressure will result in insufficient air that can cause icing of the coil, whereas too much air can cause poor humidity control, and condensate to be pulled off the evaporator coil causing condensate leakage. Too much air can cause motor overloading and in many cases this constitutes a poorly designed system. To determine proper air movement, proceed as follows:

1. Using a draft gauge (inclined manometer) measure the static pressure of the return duct at the inlet of the unit, (Negative Pressure).

S-201 CHECKING TEMPERATURE RISE

Temperature rise is related to the BTUH output of the unit and the amount of air (CFM) circulated over the indoor coil.

All units are designed for a given range of temperature increase. This is the temperature of the air leaving the unit minus the temperature of the air entering the unit.

The more air (CFM) being delivered through a given unit the less the rise will be; so the less air (CFM) being delivered, the greater the rise. The temperature rise should be adjusted in accordance to a given unit specifications and its external static pressure.

1. Take entering and leaving air temperatures.

2. Select the proper speed tap from the unit's blower performance data in the Technical Manual for the specific unit.

3. Take motor amperage draw to determine that the motor is not overloaded during adjustments.

Supply

Return

Total External Static

2. Measure the static pressure of the supply duct, (Positive Pressure).

3. Add the two readings together.

NOTE: Both readings may be taken simultaneously and read directly on the manometer as shown in the illustration above, if so desired.

4. Consult proper table for quantity of air.

If the external static pressure exceeds the minimum or maximum allowable statics, check for closed dampers, dirty filters, undersized or poorly laid out ductwork.

SUPPLY

RETURN

RISE = SUPPLY -TRETURN

Checking Temperature Rise

WIRING DIAGRAMS

PACKAGE SYSTE M WIRING DIAGRAM - 1 STAGE ELECTRIC HEAT

SEE NOTE 1

#18 GAUGE 7 WIRE

REQUIRED FOR

HEAT PUMPS

ROOM THERMOSTAT

CW1GRE

PACKAGE UNIT

LOW VOLTAG E

JUNCTION BOX

R Y G

R Y

YELLOW GREEN

ORANGE

WHITE

TYPICAL HP

BLUE

OUTDOOR THERMOSTAT

CLOSE ON TEMPERATURE FALL

PACKAGE SYSTE M WIRING DI AGRAM - 2 STAGE ELECTRIC HEAT

ABOVE 10 KW

RED

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

SEE NOTE 1

#18 GAUGE 8 WIRE

FOR HEAT PUMPS

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SEE NOTE 2

ROOM THERMOSTAT

W2 C RYO W1G E

PACKAGE UNIT LOW VOLTAG E

JUNCTION BOX

RED

R Y

G O

R Y

YELLOW GREEN ORANGE

WHITE

BROWN

BLUE

OUTDOOR TH ERM OSTAT

CLOSE ON TEMPERATURE FALL

TYPICAL HP

NOTES:

1) "O" and "E" us ed on heat pumps only.

2) Connect wire from terminal #1 on outdoor thermostat to the white wire on package uni ts if sing l e stage indoor thermostat is used.

Color Codes

R - Red Y - Yellow BL - Blue BR - Brown O - Orange W - White G - Green

OT18-60A OUTDOOR THERMOSTAT

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

WIRING DIAGRAMS

PACKAGE SYSTEM WIRING DIAGRAM - HEAT PUMPS ONLY!

TWO-STAGE ELECTRIC HEAT ABOVE 10 kW

TYPICAL H/P

ROOM THERMOST AT

W2 C RYO W1G E

#18 GAUGE 8 WIRE

PACKAGE HE AT PUMP

OUTDOO R TH ERMOSTAT #2 (IF USED, SEE NOTE 1)

OUTDOOR THERMOSTAT #1

CLOSE ON TEMPERATURE FALL

Y G

R Y

LOW VOLT AGE JUNCTI ON BOX

RED

YELLOW

GREEN

ORANGE

WHITE

BROWN

BLUE

HIGH VOLTAGE!

For outdoor temperatures below 0° F with 50% or higher relative humidity, set outdoor thermostat at 0° F

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

NOTE 1: OT18 #2 CAN BE CONNECTED BETWEEN W2 OF THERMOSTAT AND BROWN WIRE IF DESIRED.

OT18-60A OUTDOOR THERMOSTAT

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

COLOR CODES R --RED Y --YELLOW BL-BLUE BR-BROWN O --ORANGE W -WHITE G --GREEN

WIRING DIAGRAMS

DP[13-14]CH/HH**41*

L1 L2

HTR1

M1M2M3

PLM

1 2 3

4 5 6 7 8

HTR2

ONE (1) ELEMENT ROWS TWO (2) ELEMENT ROWS

L2L1

PLM

1 2 3

4 5 6 7 8 9

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

5 KW

10 KW

FL FL FL

PLM

M1 M2

2 3

5 6

7 8 9

HTR1

HTR2

HTR3

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

HTR1

HTR2 HTR3

HTR4

M1 M2

TL TL TL

M5 M6

M7 M8

BL BR

PLM

1 2 3 4 5 6 7 8 9

L2 L1 L2

THREE (3) ELEMENT ROWS FOUR (4) EL EMENT ROWS

L2L1 L1 L2

15 KW

20 KW

SINGLE PHASE HKR/HKP HEAT KIT

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

WIRING DIAGRAMS

DP[13-14]CH/HH**41*

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

ECONOMIZER FOR DP[13-14]CH/HH**41*

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

WIRING DIAGRAMS

TO CONTROL BOX

SEE NOTES 1 & 2

PU/BK-3

CCB

TO ELECTRIC HEAT

BK-3

COLOR CODE

BK --------------- BLACK

GR---------------- GREEN

BR --------------- BROWN

PU --------------- PURPLE

WH -------------- WHITE

WIRINGCODE

FACTORY WIRING

HIGH VOLTAGE

OPTIONAL HIGH VOLTAGE

FIELD WIRING

HIGH VOLTAGE

0140G02544-A

YL --------------- YELLOW

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

208 / 240 / 1 / 60

SPB

NOTES:

1. FOR DP13/14C UNITS: A = L1 / B = L2

FOR DP13/14C UNITS: A = L2 / B = L1

2. 45, 40, 35, & 30 AMP BREAKERS WILL

SPK* - SINGLE POINT WIRING KIT

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

HAVE A PURPLE WIRE. 50 AND 60

AMP BREAKERS WILL HAVE BLACK

WIRE LABELED WITH A #3

CCB - COMPRESSOR

CIRCUIT BREAKER

LEGEN

SPB - SINGLE POINT BLOCK

WIRING DIAGRAMS

(

DP14CH[24-48]41**

SEE NOTE 2

G N

IF USED) SEE NOTE 4

RCCF

NOTE #3

LVJB

RD GR WH

SEE NOTE 5

GND

O S

W2 C

CONTROL BOX

PLF

COMP

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

NOTE #2

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

4 5 6

SUPPLY VOLTAGE

COMP

S.A.

IF USED

NOTE #4

R W2 W1 Y G C

208-240/1/60

RCC F

NOTE #4

208-240

3 1

24V

SEE NOTE #2

COMPONENT LEGEND

CONTACTOR

COND ENSER MOTOR

COMP

COMPRESSOR

EVAPORATOR MOTOR

GND

EQUIPMENT GROUND

LVJB

LOW VOLTAGE JUNCTION BOX

PLF

FEMALE PLUG / CONNECTOR

RCCF

RUN CA PACITOR FOR^J COMPRESSOR AND FAN

START ASSIST

TRANSF ORMER

FACTORY WIRING LINE VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLTAGE

FIELD WIRI NG HIGH VOLTAGE LOW VOLTAGE

WIRE CODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW

NOTES:

1. REPLACEMENT WIRE MU ST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL (AT LEAST 105°C) USE COPPER CONDUCTOR ONLY.

2. TO C HANGE EV APORATOR MOTOR SPEED MOVE WHITE AND YELLOW LEADS FROM EM "2" AND "3" TO "4" AND "5". IF BOTH LEADS ARE ENERGIZE D, THE HI G HER SPEED S ETTING IS USED.

3. FOR 208 VO LT TRANSFORMER OPE RATION MOVE PU RPLE WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

4. START ASSIST FACTORY EQUIPPED W HEN REQUIRE D

5. USE C OPP ER CONDUC TORS ONLY. ++ USE N.E.C. CLASS 2 WIRE

SEE UNIT RATING PLATE FOR TYPE AND SI ZE

OF OVER CURRENT PROTECTION

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

WIRING DIAGRAMS

DP14CH[48-60]41B*

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

4 5

NOTE #2

SUPPLY VOLTAGE

COMPC

S.A.

IF USED

NOTE#3

C L G N 1

2 3

SEENOTE 2

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SA (IFUSED)SEENOTE4

208-240/1/60

RCCF

NOTE#4

208-240

3 1

24V

208

24V

RCCF

NOTE #3

YL GR

EQUIPMENTGROUND FIELD GROUND

FIELDSPLICE SWITCH (TEMP) IGNITER

SEENOTE 5

GND

LVJB

HPS

ACTORY WIRING

FIELDWIRING

WIRECODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH WHITE YL YELLOW

T H

O S

A T

CONTROL BOX

LINE VOLTAGE LOW VOLTAGE

OPTIONAL HIGH

VOLTAGE

HIGH VOLTAGE LOW VOLTAGE

2 0 8

2 4 0

240

PLF

562 41

INTEGRATEDCONTROL

COMPONENT

LEGEND

BLOWER INTERLOCK RELAY

CONTACTOR

CRACKCASE HEATER

CONDENSERMOTOR

COMP

COMPRESSOR

EBTDR

ELECTRONICBLOWERTIMEDELAY RELAY

EVAPO RATOR MOTOR

FANCAPACITOR

GND

EQUIPMENT GROUND

LVJB

LOW VOLTAGEJUNCTION BOX

PLF

FEMALE PLUG / CONNECTOR

RCCF

RUNCAPACITORFOR COMPRESSORAND FAN

START ASSIST

TRANSFORMER

HPS

HIGHPRESSURESWITCH

JUNCTION TERMINAL

INTERNALTO

PLUGCONNECTION

SWITCH(PRESS.)

OVERCURRENT

PROT. DEVICE

COMP

PLF

SEENOTE #2

2 3

4 5 6

HPS

R W2 W1 Y G C

THERMOSTAT

OTES:

1. REPLACEMENT WIRE MUST BE SAMESIZE AND TYPE INSULATIONAS ORIGINAL (ATLEAST 105°C) USE CO PPERCON DUCTOR ONL Y.

2. TO CHANGEEV AP ORATORM O TORSPEEDREPLACE LEAD ONEBTDR"COM"WITH LEAD ON EBTD R"M 1 "OR "M2"

3. FOR208 VOLT TRANSFORMER OPERATIONMOVE PURP LE WIRES FROM TERMINAL 3 TERMINAL 2 ON TRANSFORMER.

4. START ASSIST FA CTO REQUIPEDWHENREQUIRED

5. USE COPPERCONDUCTORS ONL Y

++USEN.E.C.CLASS2 WIRE

SEE UNIT RATING PLATE FOR TYPE AND SIZE

OF OVER CURRENT PROTECTION

208-240/1/60 0140G00871-C

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

WIRING DIAGRAMS

DP14HH[24-60]41A*/B*

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

SEE NOTE 8

SEE NOTE 7

SEE NOTE 5

GND

LVJB

RD GR WH

SEE NOTE 6

SEE NOTE 2

240

SA SEE NOTE 4

HPS

SEE NOTE 3

PLF

562

COMP

RCCF

CONTROL BOX

208

24V

RDYL

LPS

YL/PK

CCR

LVDR

CNT

0-RV

C-RV

PS2

DFT

RVC

DFT

DF2

R-PS1

R-DFT

C D

HVDR

DF1

L G N

4 5

COMPONENT LEGEND

CONTACTOR

CCR

COMPRESSOR CONTACTOR RE LAY

SEE NOTE 2

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

4 5

L 7

S.A.

SEE NOTE 4

SEE NOTE 3

SUPPLY VOLTAGE

208-240/1/60

COMP

CHS

208-240

1 3

RCCF

SEE NOTE 6

DF1

HVDR

DF2

NOTES:

1. REPLACEMENT WIRE MUST BE SAME SIZE AND TYPE INSULATION AS ORIGINAL (AT LEAST 105°C) USE COPPER CONDUCTOR ONLY.

2. TO CHANGE EVAPORATOR MOTOR SPEED MOVE WHITE AND YELLOW LEADS FROM EM"2" AND "3" TO "4" AND "5". IF BOTH LEADS ARE ENERGIZED, THE HIGHER SPEED SETTING IS USED. 3 FOR 208 VOLT TRANSFORMER OPERATION MOVE PURPLE WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

4. START ASSIST FACTORY EQUIPPED WHEN REQUIRED

5. USE COPPER CONDUCTO RS ONLY

6. CRANKCASE HEATER AND CRANKCASE HEATER SWITCH FACTORY EQUIPPED WHEN REQUIRED.

7. DOUBLE POLE CO NTACTOR SHOWN. SINGLE POLE CONTACTOR COULD BE FACTORY EQUIPPED AS AN ALTERNATE CONFIGURATION.

8. COMMON SIDE OF CONTACTOR CAN NOT BE GROUNDED OR CONNECTED TO ANY OTHER COMMON (24V).

CRACKCASE HEATER

CHS

CRACKCASE HEATER SW ITCH

CONDENSER MOTOR

COMP

COMPRESSOR

DEFROST CONTROL

DFT

DEFROST THERMOSTAT

EVAPORATOR MOTOR

GND

EQUIPMENT GROUND

HVDR

HIGH VOLTAGE DEFROST RELAY

LPS

LOW PRESSURE SW ITCH

LVDR

LOW VOLTAGE DEFROST RELAY

LVJB

LOW VOLTAGE JUNCTION BOX

PLF

FEMALE PLUG / CONNECTOR

RVC

REVERSING VALVE COIL

RCCF

RUN CAPACITOR FOR COMPRESSOR AND FAN

START ASSIST

TRANSFORMER

HPS

HIGH PRESSURE SWI TCH

JUNCTION

TERMINAL

INTERNAL TO

INTEGRATED CONTROL

PLUG CONNECTION

IGNITER

SWITCH (PRESS.)

OVERCURRENT PROT. DEVICE

USE N.E.C. CLASS 2 WIRE

SEE UNIT RATING PLATE FOR TYPE AND SIZE

OF OVER CURRENT PROTECTION

EQUIPMENT GROUND

FIELD GROUND

FIELD SPLICE

SWITCH (TEMP)

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

2 0 8

2 4 0

SEE NOTE 6

FACTORY WIRING LINE VOLTAGE LOW VOL TAGE OPTIONAL HIGH VOLTAGE

FIELD WIRING HIGH VOLTAGE LOW VOL TAGE

WIRE CODE BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PU PURPLE RD RED WH W HITE YL YELLOW

0140G01640-C

Daikin DP 13, DP 14 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual