Friedrich PE07R, PE15K, PE12R, PE09K, PE09R Service Manual

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Service Manual
WallMaster® P SERIES
· Standard Unit
· Seacoast Protected Unit
· Remote Thermostat Unit
P2K23-DM (4-03)
3
Table of Contents
Typical Unit Components .......................................... 4
Introduction................................................................ 4
Unit Identication....................................................... 5
Unit Specications..................................................... 6
PE Series Air Conditioner–Cooling Performance...... 6
PH Series Heat Pump–Heating/Cooling Performance..... 6
PE / Ph Series Electric Heating Data ........................ 6
Sequence Of Operation............................................. 7
Electrical Supply........................................................ 8
Supply Circuit ............................................................ 8
Electrical Rating Tables ............................................. 8
Standard Unit Operation............................................ 9
Temperature Limiting Thermostat.............................. 9
Standard Unit Control Panel...................................... 9
Remote Thermostat Unit Installation ....................... 10
Manual Changeover Thermostat............................. 10
Remote Thermostat Unit Operation..........................11
Room Thermostats...................................................11
Location....................................................................11
Heat Anticipators ..................................................... 12
Calculating Approximate CFM................................. 12
Fan Cycle Switch..................................................... 13
Hot Start Sensor...................................................... 13
Refrigerant Charging ............................................... 13
Method Of Charging ................................................ 13
Undercharged Refrigerant Systems ........................ 14
Overcharged Refrigerant Systems .......................... 15
Restricted Refrigerant Systems............................... 18
Capillary Tube Systems........................................... 17
Reversing Valve Operation ...................................... 17
Electrical Circuit And Coil ........................................ 18
Checking Reversing Valve....................................... 18
Touch Test In Heating/Cooling Cycle....................... 18
Procedure For Changing Reversing Valve .............. 18
Compressor Checks................................................ 19
Locked Rotor Voltage (L.R.V.) Test ......................... 19
Single Phase Connections ...................................... 19
Determine L.R.V. ..................................................... 19
Amperage (L.R.A.) Test ........................................... 19
Single Phase Running And L.R.A. Test ................... 19
External Overload.................................................... 19
Checking The External Overload............................. 19
Single Phase Resistance Test ................................. 20
Compressor Replacement....................................... 20
Capacitors ............................................................... 21
Capacitor Check ..................................................... 21
Capacitor Connections ............................................ 21
System Switch Continuity Check............................ 22
Thermostat Continuity Check .................................. 22
Fan Cycle Switch Continuity Check ........................ 23
Fan Speed Switch Continuity Check ....................... 23
Emergency Heat Switch Continuity Check.............. 24
Routine Maintenance .............................................. 25
Troubleshooting Chart — Cooling .......................... 26
Troubleshooting Chart — Heating.......................... 27
Electrical Troubleshooting Chart ............................. 28
Wiring Diagrams................................................. 29-34
2
Typical Unit Components
Discharge Air Grille
Filters
Return Air Grille
Blower Wheel
Indoor Blower Housing
Gasket
Control Door
Evaporator Coil
Front Cover
Condenser
Control Panel
Condenser Fan Blade
Shroud
Gasket
Condenser
Coil
Compressor
Basepan
Outdoor Grille
Wall Sleeve
INTRODUCTION
This service manual is designed to be used in conjunction with the installation manuals provided with each air conditioning system component.
This service manual was written to assist the professional HVAC service technician to quickly and accurately diagnose and repair any malfunctions of this product.
This manual, therefore, will deal with all subjects in a general nature. (i.e. All text will pertain to all models).
IMPORTANT: It will be necessary for you to accurately identify the unit you are
servicing, so you can be certain of a proper diagnosis and repair. (See Unit Identication.)
The information contained in this manual is intended for use by a qualied service technician who is familiar with the safety procedures required in installation and repair, and who is equipped with the proper tools and test instruments.
Installation or repairs made by unqualied persons can result in hazards subjecting the unqualied person making such repairs to the risk of injury or electrical shock which can be serious or even fatal not only to them, but also to persons being served by the equipment.
If you install or perform service on equipment, you must assume responsibility for any bodily injury or property damage which may result to you or others. Friedrich Air Conditioning Company will not be responsible for any injury or property damage arising from improper installation, service, and/or service procedures.
3
5
UNIT IDENTIFICATION
Model Number Code
P H 07 K 3 S B 1
Series
P = P series
System
X= Accessory E= Cooling with or without electric heat H = Heat Pump with Auxiliary Heat
Nominal Cooling Capacity
07 = 7,000 - 7,100 BTUh 09 = 9,000 - 9,100 BTUh 12 = 11,500 - 11,700 BTUh 15 = 14,100 - 14,200 BTUh
Engineering Digit
Design Series
Options
S = Standard R = Remote Thermostat C = Seacoast Protection X = Seacoast Remote
Nominal Heater Size
(@ 230V or 265V) 0 = No Heater 2 = 2.5 KW 3 = 3.4 KW 5 = 5.0 KW
Voltage
K = 230/208V - 1Ph. - 60 Hz. R = 265V - 1Ph. - 60 Hz.
PTAC Serial Number Identication Guide
Serial Number
Decade Manufactured
L=0 C=3 F=6 J=9 A=1 D=4 G=7 B=2 E=5 H=8
Year Manufactured
A=1 D=4 G=7 K=0 B=2 E=5 H=8 C=3 F=6 J=9
Month Manufactured
A=Jan D=Apr G=Jul K=Oct B=Feb E=May H=Aug L=Nov C=Mar F=Jun J=Sep M=Dec
4
L B L P 00000
Production Run Number
PRODUCT LINE R=RAC
P=PTAC E=EAC V=VPAK H=Split
GENERAL INFORMATION – PE SERIES
Model PE07K PE07R PE09K PE09R PE12K PE12R PE15K PE15R
POWER
VOLTAGE (1 PHASE, 60 Hz) 230/208 265 230/208 265 230/208 265 230/208 265
VOLT RANGE 253-198 292-239 253-198 292-239 253-198 292-239 253-198 292-239
POWER (WATTS) 615/598 615 800/783 800 1091/1073 1091 1579/1578 1579
CURRENT (AMPS) 3 3 3.9 3.9 5.1 5.1 6.6 6.6
POWER FACTOR 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9
AMPS L.R. 18 18 22.2 22.2 26.3 26.3 38 38
AMPS F.L. 3 3 3.9 3.9 5.1 5.1 6.8 6.8
HORSEPOWER 1/15. 1/15. 1/12. 1/12. 1/10. 1/10. 1/10. 1/10.
R-22 CHARGE (OZ) 27 27 30 30 28 28 28 28
PERFORMANCE
COOLING BTUh 7500/7300 7500 9200/9000 9200 12000/11800 12000 15000/14800 15000
INDOOR CFM 250 250 300 300 325 325 350 350
SENSIBLE HEAT RATIO 0.79 0.79 0.76 0.76 0.76 0.76 0.75 0.75
VENT CFM 60 60 60 60 70 70 70 70
GENERAL INFORMATION – PH SERIES
Model PH07K PH07R PH09K PH09R PH12K PH12R PH15K PH15R
POWER
VOLTAGE (1 PHASE, 60 Hz) 230/208 265 230/208 265 230/208 265 230/208 265
VOLT RANGE 253-198 292-239 253-198 292-239 253-198 292-239 253-198 292-239
POWER (WATTS) 590/574 590 791/774 791 1121/1023 1121 1581/1559 1559
CURRENT (AMPS) 3 3 3.9 3.9 5.1 5.1 6.6 6.6
POWER FACTOR 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9
AMPS L.R. 18 18 22.2 22.2 26.3 26.3 38 38
AMPS F.L. 3 3 3.9 3.9 5.1 5.1 6.8 6.8
HORSEPOWER 1/15. 1/15. 1/12. 1/12. 1/10. 1/10. 1/10. 1/10.
R-22 CHARGE (OZ) 27 27 32 32 34.5 34.5 33 33
PERFORMANCE
COOLING BTUh 7200/7000 7000 9100/8900 9100 12000/11800 12000 14700/14500 14700
REVERSE HEATING BTUh 6400/6200 6400 8100/7900 8100 10800/10600 10800 13500/13300 13500
INDOOR CFM 250 250 300 300 325 325 350 350
SENSIBLE HEAT RATIO 0.79 0.79 0.76 0.76 0.76 0.76 0.75 0.75
VENT CFM 60 60 60 60 70 70 70 70
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7
Sequence of Operation
A good understanding of the basic operation of the refrigeration system is essential for the service technician. Without this understanding, accurate troubleshooting of refrigeration system problems will be more difcult and time consuming, if not (in some cases) entirely impossible. The refrigeration system uses four basic principles (laws) in its operation they are as follows:
1. "Heat always ows from a warmer body to a cooler body."
2. "Heat must be added to or removed from a substance before a change in state can occur"
3. "Flow is always from a higher pressure area to a lower pressure area."
4. "The temperature at which a liquid or gas changes state is dependent upon the pressure."
The refrigeration cycle begins at the compressor. Starting the compressor creates a low pressure in the suction line which draws refrigerant gas (vapor) into the compressor. The compressor then "compresses" this refrigerant, raising its pressure and its (heat intensity) temperature.
The refrigerant leaves the compressor through the discharge Line as a hot High pressure gas (vapor). The refrigerant enters the condenser coil where it gives up some of its heat. The condenser fan moving air across the coil's nned surface facilitates the transfer of heat from the refrigerant to the relatively cooler outdoor air.
When a sufcient quantity of heat has been removed from the refrigerant gas (vapor), the refrigerant will "condense" (i.e. change to a liquid). Once the refrigerant has been condensed (changed) to a liquid it is cooled even further by the air that continues to ow across the condenser coil.
The PTAC design determines at exactly what point (in the condenser) the change of state (i.e. gas to a liquid) takes place. In all cases, however, the refrigerant must be totally condensed (changed) to a Liquid before leaving the condenser coil.
The refrigerant leaves the condenser Coil through the liquid line as a warm high pressure liquid. It next will pass through the refrigerant drier (if so equipped). It is the function of the drier to trap any moisture present in the system, contaminants, and large particulate matter.
The liquid refrigerant next enters the metering device. The metering device is a capillary tube. The purpose of the metering device is to "meter" (i.e. control or measure) the quantity of refrigerant entering the evaporator coil.
In the case of the capillary tube this is accomplished (by design) through size (and length) of device, and the pressure difference present across the device.
Since the evaporator coil is under a lower pressure (due to the suction created by the compressor) than the liquid line, the liquid refrigerant leaves the metering device entering the evaporator coil. As it enters the evaporator coil, the larger area and lower pressure allows the refrigerant to expand and lower its temperature (heat intensity). This expansion is often referred to as "boiling". Since the unit's blower is moving indoor air across the nned surface of the evaporator coil, the expanding refrigerant absorbs some of that heat. This results in a lowering of the indoor air temperature, hence the "cooling" effect.
The expansion and absorbing of heat cause the liquid refrigerant to evaporate (i.e. change to a gas). Once the refrigerant has been evaporated (changed to a gas), it is heated even further by the air that continues to ow across the evaporator coil.
The particular system design determines at exactly what point (in the evaporator) the change of state (i.e. liquid to a gas) takes place. In all cases, however, the refrigerant must be totally evaporated (changed) to a gas before leaving the evaporator coil.
The low pressure (suction) created by the compressor causes the refrigerant to leave the evaporator through the suction line as a cool low pressure vapor. The refrigerant then returns to the compressor, where the cycle is repeated.
Suction Line
6
Evaporator Coil
Metering Device
Refrigerant Strainer
Discharge Line
Compressor
Refrigerant Drier
Condenser Coil
Liquid Line
Electrical Rating Tables
All 230/208 volt units are equipped with power cords.
NOTE: Use Copper Conductors ONLY Wire sizes are per NEC, check local
codes for overseas applications
Table 1 250 V Receptacles and Fuse Types
AMPS 15 20 * 30
RECEPTACLE
MANUFACTURER PART NUMBERS
Hubbell 5661 5461 9330 P & S 5661 5871 5930 GE GE 4069-1 GE4182-1 GE4139-3 Arrow-Hart 5661 5861 5700
TIME-DELAY TYPE FUSE 15 20 30
(or HACR circuit breaker)
HACR — Heating, Air conditioning, Refrigeration * May be used for 15 Amp applications if fused for 15 Amp
NOTE: 265 volt units are permanently connected.
Table 2
Recommended branch circuit wire sizes
Nameplate
AWG Wire size**
maximum circuit
breaker size
15 14 20 12 30 10
AWG — American Wire Gauge * Single circuit from main box ** Based on copper wire, single insulated conductor at 60°C
Wire Size Use ONLY wiring size recommended for single outlet branch circuit.
Fuse/Circuit Use ONLY type and size fuse or HACR circuit breaker indicated on unit's rating plate. Proper
Breaker current protection to the unit is the responsibility of the owner.
NOTE: A time delay fuse is provided with 265V units.
Grounding Unit MUST be grounded from branch circuit through service cord to unit, or through separate ground
wire provided on permanently connected units. Be sure that branch circuit or general purpose outlet
is grounded.
Receptacle The eld supplied outlet must match plug on service cord and be within reach of service cord.
Refer to Table 1 for proper receptacle and fuse type. Do NOT alter the service cord or plug. Do
NOT use an extension cord.
Wire Sizing Use recommended wire size given in Table 2 and install a single branch circuit. All wiring must
comply with local and national codes. NOTE: Use copper conductors only.
Electric shock hazard.
Turn off electric power before service or installation.
All electrical connections and wiring MUST be installed by a qualied electrician and conform to the National Electrical Code and all local codes which have jurisdiction.
Failure to do so can result in property damage, personal injury and/or death.
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9
Standard Unit Operation
Rotary Switch Operation
Rota t e the te m p e r a t u r e dial i n small increments in the warmer or cooler direction. Moving the dial more than 1/4" at a time may overcompensate and result in an extreme hot or cold situation.
Standard Unit Control Panel
Control
Temperature
Low and High Cool
Low and High Heat
Fan Only
Operation
The full-range thermostat maintains room temperature at the desired setting in both the heating and cooling modes. Turn the dial counterclockwise for warmer and clockwise for a cooler temperature.
Operates the unit on cooling. Cooling will not begin if the room temperature is below 60°F.
Operates the unit on heating. Some models do not provide this selection.
Circulates air within the room at high fan speed only. No heating or cooling functions are active.
COOLING ONLY MODEL
Temperature Limiting Thermostat
1. Set the thermostat knob to center of dial.
2. Remove the four screws holding the control panel. Pull up
on the thermostat knob and remove it.
3. Locate the two temperature limiting screws. These screws
are factory installed for a maximum temperature range of 60°­90°F. Each hole in the dial plate represents approximately a 4° change from the adjacent hole.
4. To adjust the temperature range, move the temperature
limiting screws to the desired location.
5. Replace the knob when the desired range has been set.
6. Replace the control panel.
EXAMPLE: To set a maximum temperature range of
approximately 64° to 86°F, move the screws to the locations shown in the diagram at right.
8
HEAT/COOL MODEL
Remote Thermostat Unit Installation
1. Remote Thermostat Selection & Wiring Guidelines for Packaged
Terminal Air Conditioners
Follow the instructions and recommendations of the thermostat manufacturer for installation and wiring. Do not
use a conventional heat pump thermostat with emergency electric heat selection for our heat pump units. Our units make an automatic decision about turning on electric heat if the heating demand cannot be met by the heat pump due to low outdoor temperatures.
Manual Changeover Thermostat
For Heat Pump equipped units: A single stage, heat/cool thermostat with a terminal for a reversing valve operation
is required. Terminal "B" should be continuously energized in the heat mode and terminal "G" should be energized whenever there is a call for heating or cooling. Typically, a heat/cool thermostat designed for use with electric heat systems will meet the above requirements.
NOTE: This unit is designed for use with a single stage thermostat only. Improper application of the
thermostat may result in property damage, personal injury or death.
Honeywell Thermostat Terminal Designation
TERMINAL LETTER
Y W
(Heat Pump units Only)
For Non-Heat Pump equipped units: A single stage cooling and heating thermostat is required. Terminal "G"
should be energized whenever a call for heating or cooling is made. Typically a heat/cool thermostat designed for use with electric heat systems will meet this requirement.
G
C (common)
R
B
OPERATION
Cooling Heating
Common Terminal
24 V to the thermostat
Fan
Reversing Valve
CONTACT MADE
During call for cooling. During call for heating. Continuous if the slider is in the "Fan" position, otherwise, intermittent. For thermostats requiring a common terminal
Directly from the transformer
Made continuously during call for heating.
Simplified Wiring Example
Unit Terminal Board
* A-Sufx models do not have a "C" terminal
Terminal "C" is not used on RT1 thermostat
Terminal "B" is used for heat pump models only.
NOTE: It is the installer's responsibility to ensure that all control wiring connections are made in accordance with
the installation instructions. Improper connection of the thermostat control wiring and/or tampering with the unit's internal wiring can void the equipment warranty and may result in property damage, personal injury or death. Other manufacturer's PTACs and even older Friedrich models may have different control wire connections. Questions concerning proper connections to the unit should be directed to the factory.
Thermostat Terminals
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11
Remote Thermostat 208V Operation
208V 60HZ
If the supply voltage is 208V, the low voltage transformer MUST be wired for 208V operation. Failure to do so will result in lower control voltages to the unit and can damage low voltage components.
The simplied connection diagram at left shows the factory congured wiring set for 240V operation. If you are going to use 208V exclusively, switch the two (2) black wires on the 240V post of the primary side of the transformer to the 208V post. This will ensure correct secondary (low) voltages for the unit. This is only required on remote thermostat units.
Remote Thermostat Unit Operation
These units are controlled by the use of a remote thermostat that will cycle the unit to maintain desired room temperature. See thermostat operating instruction sheet for details.
The fan speed switch controls high and low speed fan operation. It is located on the control panel and is independent of the thermostat.
Room Thermostats
Room thermostats are available from several different manufacturers in a wide variety of styles. They range from the very simple Bimetallic type to the complex electronic set-back type. In all cases, no matter how simple or complex, they are simply a switch (or series of switches) designed to turn equipment (or components) "ON" or "OFF" at the desired conditions.
An improperly operating, or poorly loca ted room thermostat can be the source of perceived equipment problems. A careful check of the thermostat and wiring must be made then to insure that it is not the source of problems.
the oor in an area of average temperature, with good air circulation. Close proximity to the return air grille is the best choice.
Mercury bulb type thermostats MUST be level to control temperature accurately to the desired set-point. Electronic digital type thermostats SHOULD be level for aesthetics.
Thermostat Location
Location
The thermostat should not be mounted where it may be affected by drafts, discharge air from registers (hot or cold), or heat radiated from the sun or appliances.
The thermostat should be located about 5 Ft. above
10
Measuring Current Draw
Heat Anticipators
Heat anticipators are small resistance heaters (wired in SERIES with the "W" circuit) and built into most electromechanical thermostats. Their purpose is to prevent wide swings in room temperature during system operation in the HEATING mode. Since they are wired in series, the "W" circuit will open if one burns out preventing heat operation.
The heat anticipator provides a small amount of heat to the thermostat causing it to cycle (turn off) the heat source just prior to reaching the set point of the thermostat. This prevents exceeding the set point.
If a low range ammeter is not available, a "Clamp-on" type ammeter may be used as follows:
1. Wrap EXACTLY ten (10) turns of wire around the jaws of a clamp-on type ammeter.
2. Connect one end of the wire to the "W" terminal of the thermostat sub-base, and the other to the "R" terminal.
3. Turn power on, and wait approximately 1 minute, then read meter.
4. Divide meter reading by 10 to obtain correct anticipator setting.
Electronic thermostats do not use a resistance type anticipator. These thermostats use a microprocessor (computer) that determines a cycle rate based on a program loaded into it at the factory.
Calculating The Approximate CFM
The approximate CFM actually being delivered can be calculated by using the following formula:
KILOWATTS x 3413
Temp. Rise x 1.08
In order to accomplish this, the heat output from the anticipator must be the same regardless of the current owing through it. Consequently, some thermostats have an adjustment to compensate for varying current draw in the thermostat circuits.
The proper setting of heat anticipators then is important to insure proper temperature control and customer satisfaction. A heat anticipator that is set too low will cause the heat source to cycle prematurely possibly never reaching set point. A heat anticipator that is set too high will cause the heat source to cycle too late over shooting the set point.
The best method to obtain the required setting for the heat anticipator, is to measure the actual current draw in the control circuit ("W") using a low range (0-2.0 Amps) ammeter. After measuring the current draw, simply set the heat anticipator to match that value.
DO NOT simply use the Kilowatt Rating of the heater (i.e.
2.5, 3.4, 5.0) as this will result in a less-than-correct airow
calculation. Kilowatts may be calculated by multiplying the measured voltage to the unit (heater) times the measured current draw of all heaters (ONLY) in operation to obtain watts. Kilowatts are then obtained by dividing by 1000.
EXAMPLE: Measured voltage to unit (heaters) is 230 volts. Measured Current Draw of strip heaters is 11.0 amps.
230 x 11.0 = 2530 2530/1000 = 2.53 Kilowatts
2.53 x 3413 = 8635
Supply Air 95°F Return Air 75°F Temperature Rise 20°
20 x 1.08 = 21.6
8635
21.6
= 400 CFM
= CFM
11
13
Fan Cycle Switch
NOTE: It is recommended that this switch be set in the continuous position for maximum comfort and
temperature control.
The fan cycle switch is located behind the decorative front cover below the control box. It is designed to operate the fan either continuously or intermittently with the compressor or heating elements. When the switch is in the CONTINUOUS position, the fan will run continuously when the unit is turned on. With the fan cycle switch in the CYCLE position, the fan will run only when the compressor or heating elements cycle on.
Hot Start Sensor
(Heat Pump Models Only)
Under cold room conditions, the Hot Start Sensor brings on the heater strips with a call for heat. This is to dis­tribute warm air at the beginning of the heat cycle. Once the return air has warmed sufciently, the heat pump
mode will begin.
Refrigerant Charging
NOTE: Because The Ptac System Is A Sealed System, Service Process Tubes Will Have To Be Installed. First Install A Line Tap And Remove Refrigerant From System. Make Necessary Sealed System Repairs And Vacuum System. Crimp Process Tube Line And Solder End Shut. Do Not Leave A Service Valve In The Sealed System.
Proper refrigerant charge is essential to proper unit operation. Operating a unit with an improper refrigerant charge will result in reduced performance (capacity) and/or efciency. Accordingly, the use of proper charging methods during servicing will insure that the unit is functioning as designed and that its compressor will not be damaged.
Too much refrigerant (overcharge) in the system is just as bad (if not worse) than not enough refrigerant (undercharge). They both can be the source of certain compressor failures if they remain uncorrected for any period of time. Quite often, other problems (such as low air ow across evaporator, etc.) are misdiagnosed as refrigerant charge problems. The refrigerant circuit diagnosis chart will assist you in properly diagnosing these systems.
Not enough refrigerant (undercharge) on the other hand, will cause the temperature of the suction gas to increase to the point where it does not provide sufcient cooling for the compressor motor. When this occurs, the motor winding temperature will increase causing the motor to overheat and possibly cycle open the compressor overload protector. Continued overheating of the motor windings and/or cycling of the overload will eventually lead to compressor motor or overload failure.
Method Of Charging
The acceptable method for charging the PTAC system is the Weighed in Charge Method. The weighed in charge method is applicable to all units. It is the preferred method to use, as it is the most accurate.
The weighed in method should always be used whenever a charge is removed from a unit such as for a leak repair, compressor replacement, or when there is no refrigerant charge left in the unit. To charge by this method, requires the following steps:
1. Install a piercing valve to remove refrigerant from the sealed system. (Piercing valve must be removed from the system before recharging.)
2. R e c o v e r Re f r i g e r a n t in accordance with EPA regulations.
3. Install a process tube to sealed system.
4. Make necessary repairs to system.
An overcharged unit will at times return liquid refrigerant (slugging) back to the suction side of the compressor eventually causing a mechanical failu re within the compressor. This mechanical failure can manifest itself as valve failure, bearing failure, and/or other mechanical failure. The specic type of failure will be inuenced by the amount of liquid being returned, and the length of time the slugging continues.
12
5. Evacuate system to 300 microns or less.
6. Weigh in refrigerant with the property quantity of R-22 refrigerant.
7. Start unit, and verify performance.
8. Crimp the process tube and solder the end shut.
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