Mars Air Systems L-2254 User Manual

vector compact
Installation & Operation
Direct Expansion Systems Revised: 7-18-05 L-2254
TABLE OF CONTENTS
Table of Contents
IF YOU HAVE A DIGITAL CONTROL......................................................................................................... 3
Introduction
How It Works ............................................................................................................................................... 4
Installation
Unpacking and Inspection.......................................................................................................................... 5
Safety Considerations ................................................................................................................................ 5
Placement of System ................................................................................................................................. 5
Condensate Drains..................................................................................................................................... 6
Blower Assembly ........................................................................................................................................6
Mounting Brackets ...................................................................................................................................... 6
Supply & Return Air Grilles and Transition Boxes...................................................................................... 6
Ducting........................................................................................................................................................ 6
Seawater Pump and Plumbing .................................................................................................................. 7
Electrical Connections, Grounding and Bonding ....................................................................................... 8
Manual Control Panel (MCP) Installation ................................................................................................... 8
Installation Checklist (Review prior to installation) ..................................................................................... 9
Operation
Mechanical Control Panel (MCP) Operation............................................................................................ 10
Quick Start Operations Checklist .............................................................................................................10
Troubleshooting
General Troubleshooting .......................................................................................................................... 11
Digital Controls Troubleshooting .............................................................................................................. 12
MCP Mechanical Control Panel Troubleshooting ....................................................................................14
Maintenance
Winterization ............................................................................................................................................. 15
Manufacturers Limited Warranty Agreement 16
Description of Figures 17
Distributor Listing 27
IF YOU HAVE A DIGITAL CONTROL
Please refer to either the Elite Control manual (L-2230) or the Passport I/O Control manual (L-2231) for installation and operation of those digital control panels. Mechanical control information and wiring diagrams for both types of controls are in this manual.
Copyright 2005 Dometic Environmental Corporation, All Rights Reserved - Every precaution has been taken in the preparation of this manual to insure its accuracy. However, Dometic assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of this product and information contained herein.
L-2254
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INTRODUCTION
Congratulations on the purchase of your Marine Air Systems’ Vector Compact which of the following features was the reason for your purchase of this air conditioner, we are sure it will meet your needs and will give you many years of efficient and trouble free use. The Vector Compact self-contained direct expansion air conditioners are designed for marine applications incorporating the following features:
• Patented compact design with the condenser coil in the evaporator shroud
• High efficiency rotary compressor or scroll (24K) compressors
• Cupronickel condenser coil
• Enhanced fin designed evaporator coil
• 2" deep drain pan with multiple condensate drain locations
• Anti-vibration base pad
• Pre-charged and pre-wired systems for easy connections
• Rotatable blower assembly
• Charge Guard® ensures environmental protection and system integrity
This manual is intended to provide the information necessary to ensure proper installation, operation, and maintenance of the unit. The figures that are referenced throughout this manual can be found immediately after the warranty section. Improper installation or misunder­stood operating procedures can result in unsatisfactory performance and/or premature failure of these units, so before proceeding
The Vector Compact units are covered under the existing Dometic Environmental Corporation (Dometic) warranty policy contained in this manual. In the interest of product improvement, Dometic’s specifications and design are subject to change without prior notice.
®
air conditioner. No matter
please read this manual completely.
Clean Air Act Amendments of 1990 [Title VI - Section 608(C-1)]
“Effective July 1, 1992, it shall be unlawful for any person, in the course of maintaining, servicing, repairing, or disposing of an appliance or industrial process refrigeration, to knowingly vent or otherwise knowingly release or dispose of any Class I* or Class II** sub­stance used as a refrigerant in such appliance (or industrial process refrigeration) in a manner which permits such substance to enter the environment. De minimis releases associated with good faith attempts to
recapture and recycle or safely dispose of any such substances shall not be subject to the prohibition set forth in the proceeding sentence.”
* Class I substances include CFC-12
** Class II substances include HCFC-22
Marine Air Systems
Marine Air Systems (MAS) is a product of Dometic Environmental Corporation. Dometic is a recognized leader in the design and manufacture of high-perfor­mance comfort control systems, refrigeration products and battery charging products for demanding environ­ments, including commercial and recreational marine craft, vehicles and other applications. We offer an unparalleled scope of products, dealer networks, applica­tions support, engineering resources and production capabilities throughout the world. Our team has many years of experience in the design, manufacture, applica­tion and support of our products. Our practical experi­ence and design capability allows our application engineers and sales representatives to offer optimum solutions for your environmental control requirements. Product lines also include well known Cruisair, Grunert, and Sentry.
How It Works
Your self-contained air conditioner consists of four main components and a refrigerant gas circulating through the system. The BLOWER draws warm cabin air across the fins on the EVAPORATOR where the heat from the air is transferred to the refrigerant in the evaporator coil. As the refrigerant evaporates from a liquid into a gas it absorbs the heat from the cabin air. The COMPRESSOR then compresses the refrigerant gas and pumps it through the outer tube in the CONDENSER COIL. The seawater pump circulates cool seawater through the inner tube in the condenser coil, this cools the refriger­ant and condenses it into a liquid. The heat from the refrigerant is exchanged to the seawater and discharged overboard. The liquid refrigerant is then passed through the EVAPORATOR COIL and the cycle repeats. Remov­ing heat from the cabin air lowers its temperature. The cooled air is blown through the ducting and out the supply air grille(s). For reverse cycle heating, the refriger­ant flows in the opposite direction through the reversing valve. Heat is transferred from the seawater in the condenser coil to the refrigerant and then to the air blowing through the evaporator into the cabin. Seawater temperature will directly affect the a/c unit’s efficiency. This a/c unit can effectively cool your boat in water temperatures up to 90°F and heat in water temperatures as low as 40°F. See Figure 1.
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INSTALLATION
Unpacking and Inspection
When the equipment is received, all items should be carefully checked against the packing list to ensure all cartons have been received. Move units in the normal “up” orientation as indicated by the arrows on each carton. Examine cartons for shipping damage, removing the units from the cartons if necessary. If the unit is damaged, the carrier should make the proper notation on the delivery receipt acknowledging the damage.
CAUTION: When unpacking and installing the 3-knob control (if mechanical option is used), care must be taken not to kink or break the copper cap tube when uncoiling the sensing bulb. The cap tube is hollow and kinking or sharp bends will inhibit system operation.
Safety Considerations
VERY IMPORTANT:
in the bilge or engine room areas. Insure that the selected location is sealed from direct access to bilge and/or engine room vapors. Do not terminate condensate drain line within three (3) feet of any outlet of engine or generator exhaust systems, nor in a compartment housing an engine or generator, nor in a bilge, unless the drain is connected properly to a sealed condensate or shower sump pump.
Installation and servicing of this system can be hazard­ous due to system pressure and electrical components. When working on this equipment, always observe precautions described in the literature, tags and labels attached to the unit. Follow all safety codes. Wear safety glasses and work gloves and place a fire extinguisher close to the work area. The following is a summary of the labels on the unit:
Danger
Electrical shock hazard. Disconnect voltage at main panel or power source before opening any cover. Failure to comply may result in injury or death.
Never install your air conditioner
Notice
This component is charged with hydrochloro-fluorocarbon (HCFC) refrigerant R22. Effective July 1, 1992 it shall be unlawful for any person to knowingly vent or otherwise knowingly release any class 1 (CFC) or class 2 (HCFC) substance as a refrigerant in a manner which permits such substance to enter the atmosphere per the clean air act of 1990. Public law 101-549 Title IV Section 608­C. Failure to comply may result in severe penalties, including fines and imprisonment.
Warning
To minimize the hazard of electrical shock and personal injury, this component must be effectively grounded. Refer to the installation guidelines for further information.
Caution
High compressor temperature is normal.
Do not touch.
Placement of System
Selecting a good location for your air conditioner is the most important part of your preparations. Be sure to consider the size of the area you are cooling, the air distribution needs, and the size of the unit you have chosen. Keeping in mind that cool air has a tendency to fall, it is highly recommended that you locate the supply air grille as high as possible in the cabin. See Figures 2 and 3.
The Vector Compact unit should be installed as low as possible, BUT NEVER IN THE BILGE OR ENGINE
ROOM AREAS. INSURE THAT THE SELECTED LOCA­TION IS SEALED FROM DIRECT ACCESS TO BILGE AND/OR ENGINE ROOM VAPORS. Installing the unit as
low as possible (such as under a V-berth, dinette seat or bottom of a locker) and ducting the supply air as high as possible, creates an ideal airflow condition. This type of installation will prevent short or premature cycling.
Warning
This component does not meet federal require­ments for ignition protection. Do not install in spaces containing gasoline engines, tanks, LPG/ CPG cylinders, regulators, valves or fuel line fittings. Failure to comply may result in injury or death.
L-2254 Installation
The unit should be positioned on a firm, level, horizontal surface and the condensate drain line should run downward from the unit to a suitable drain location. Plan all connections which must be made including ducting, condensate drain, seawater in and out, electrical power connections, location of control, and seawater pump placement, to assure easy access for routing and servicing.
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Minimum Tools Required
• Screws drivers
• Pliers
• Pipe wrenches
• Wire cutters/crimpers
• Drill and assorted bits
• Jig saw
• Duct tape
• Electrical tape
• Teflon tape
• Beding compound to seal thru hull fittings
• Hardware to secure unit, pump, strainer, grilles & control panel
Condensate Drains
The condensate drain pan is 2" high with up to four drain locations. During conditions of high humidity, condensate may be produced at a rate of approximately 1/2 gallon per hour. With this in mind, it is important to route condensate drains downward to a sump pump. It is not recommended to route condensate drains to the bilge. After the condensate drain installation is complete, test the installation by pouring a quart of water into the pan and checking for good flow. See Figure 4.
utilized. This will help to prevent water from standing in the pan. See item 7 for instructions on connecting two drain lines.
IMPORTANT! Do not terminate condensate drain line within three (3) feet of any outlet of engine or generator exhaust systems, nor in a compartment housing an engine or generator, nor in a bilge, unless the drain is connected properly to a sealed condensate or shower sump pump.
Blower Assembly
With the Vector Compact you can achieve multi-direc­tional supply air discharge from a single unit by rotating the blower to the desired location. It is ideal for tight installations as 130° of rotation are available with which to position the blower. Its advanced design allows the blower to be easily removed for rotating or servicing by removing the two mounting ring screws and the screws attaching the blower to the drain pan. Rotate the blower to allow the most direct flow of air to the supply air grille. Reinstall the mounting screws. Plug any unused screw holes in the blower to prevent air loss.
Mounting Brackets
The a/c unit is supplied with a base pan that also serves as a condensate pan. Mounting clip brackets are pro­vided to secure the base pan onto a flat, horizontal surface. See Figure 5.
For installation of the condensate drain:
1. Remove the aft facing watertight plug from the base pan of the a/c unit (see note).
2. Slip the solid washer and the liquid-seal washer onto the PVC fitting in that order.
3. Connect the fitting through the exposed hole in the base pan with the locking nut.
4. Securely tighten with two (2) wrenches to provide a proper seal.
5. Attach a 5/8" I.D. reinforced hose to the hose barb and secure with stainless steel hose clamps.
6. Install the condensate drain hose downhill from the unit and aft to a sump.
7. Two drain fittings may be used and the hoses teed together provided there is a minimum 2" drop form the bottom of the base pan to the tee connection.
Note: The reason to use the "aft facing" drain location is so that water will tend to drain out of the pan when the vessel is under way. However, the boat owner should inspect the pan when the vessel is at rest. If water is collecting in the pan along an edge other than "aft facing", then the drain on that edge should also be
Supply & Return Air Grilles and Transition Boxes
Install the supply air grille as high as possible in a location that will provide uniform air distribution through­out the cabin, grille louvers should be directed upward. The return air grille should be installed as low and close to the a/c unit as possible to insure direct uninterrupted airflow to the evaporator. The return air grille should have a minimum four inches (4") of clearance in front of it, free from any furniture or other obstructions. In no instance should a supply air discharge be directed towards a return air grille, as this will cause the system to short cycle. Allow for adequate clearance behind the supply air grille(s) for the transition box and ducting connection. The table in Figure 8 shows minimum grille sizes. See the MAINTENANCE section of this manual for return air filter cleaning instructions.
Ducting
Good airflow is critical for the performance of the entire system. It is highly dependent on the quality of the ducting installation.
straight, smooth and taut as possible minimizing the number of 90° bends (two tight 90° bends can reduce airflow by 25%). The table in Figure 8 shows minimum
The ducting should be run as
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duct diameters and their corresponding supply and return air grille minimum area in square inches. If a transition box is used, the total area of supply air ducts going out of the box should at least equal the area of the supply duct feeding the box. To calculate the square inch area of a round duct, multiply the radius by itself (r and multiply that number by 3.1416(π). See Figure 8.
The following is a summary of proper ducting connections:
1. Pull back the fiberglass insulation exposing the inner mylar duct hose.
2. Slide the mylar duct hose around the mount ring until it bottoms out.
3. Screw 3 or 4 stainless steel sheet metal screws through the duct hose into the transition ring.
Make sure to catch the wire in the duct hose with the heads of the screws. Do not use band clamps, as the hose will slide off.
4. Wrap duct tape around the ducting and ring joint to prevent any air leaks.
line and as close to the keel as possible in any application, but especially on a sailboat, to keep the intake in the water when the boat heels over so that air does not get into the system.
2
proper installation.)
)
The speed scoop intake must face forward and not be shared with any other pump. A seawater strainer is mandatory between the shut off valve (seacock) and the pump to protect the pump from any foreign matter.
(See Figure 7 for
Failure to install a seawater strainer will void the pump warranty.
stalled with an upward incline from the speed scoop & seacock, through the strainer, to the inlet of the pump and then up to the inlet of the a/c unit’s condenser coil. The discharge from the a/c unit should then run to the seawater outlet thru-hull fitting which should be located where it can be visually checked for water flow and as close as practicable to the waterline to reduce noise. All hose connections shall be secured by means of double/ reversed stainless steel hose clamps. Use teflon tape on all threaded connections. The following is a summary of the seawater system installation:
The seawater system should be in-
5. Pull the insulation back up over the mylar to the ring and tape this joint.
6. Remove excess ducting and use the same connection method at the supply air grille.
All ducting should:
• Be appropriately sized for each application.
• Run as smoothly and taut as possible.
• Have as few bends or loops as possible.
• Be securely fastened to prevent sagging during boat operation.
• Have all excess ducting lengths trimmed off.
• Not be flattened or kinked.
• Insulated when located in high heat load areas (hull side, mechanical compartments, etc.).
• Be properly protected against potential damage when routed through open areas.
Seawater Pump and Plumbing
Several guidelines should be followed during the installa­tion of the seawater system. Since the circulation pump is centrifugal and not self-priming, it must be mounted so that it is always at least one foot below the water line regardless of which tack the vessel is on. Pump may be mounted horizontally or vertically, however the discharge must always be above the inlet. Pump head should be rotated toward the direction of water flow.
seawater speed scoop intake as far below the water
Install the
1. Install the speed scoop thru-hull inlet as close to the keel and as far below the water line as possible, facing forward. Bed the scoop with a marine sealant de­signed for underwater use.
2. Install a bronze, full flow seacock on the speed scoop thru-hull inlet.
3. Install a seawater strainer below the level of the pump with access to filter.
4. Mount the pump above the strainer and at least one foot below the waterline.
5. Connect the seacock and strainer with an uphill run of reinforced marine grade hose.
6. Connect the discharge from the pump uphill to the bottom inlet of the a/c unit’s condenser coil with 5/8" hose. Connect the discharge from the condenser coil to the overboard discharge thru-hull fitting with 5/8" hose.
7. Avoid loops, high spots or the use of 90° elbows with seawater hose (each 90° elbow is equivalent to 2.5' of hose and a 90° elbow on the pump outlet is equivalent to 20' of hose).
8. Double clamp all hose connections with stainless steel clamps, reversing the clamps.
9. Use teflon tape on all threaded connections.
Connect all metallic parts in contact with seawater
10.
to the vessel’s bonding system including the speed scoop inlet, strainer, pump and the air conditioner. Failure to do so will void warranty.
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Electrical Connections, Grounding and Bonding
All a/c units have a terminal strip mounted inside the electric box. The terminal strip is labeled for proper connections of the electrical supply, ground wires and pump circuits. A wiring diagram is provided in the electrical box and in this manual. The wiring diagram in the electrical box supersedes the one in this manual and ABYC standards. The correct size circuit breaker should be used to protect the system as specified on the a/c unit’s data plate label. A minimum of 12 AWG boat cable should be used to supply power to the a/c unit and the seawater pump. All connections shall be made with ring or captive fork terminals. Turn off a/c power supply circuit breaker before opening electric box. See Figures 9 and 10.
Each a/c unit installed requires its own dedicated circuit breaker. If there is only one a/c unit installed, the seawater pump does not require a circuit breaker; the wiring from the seawater pump is connected to the terminal strip in the electric box. If two or more a/c units use the same seawater pump, the pump wires will be connected to a pump relay panel (PRP) which in turn has its own dedicated circuit breaker sized for the pump (20 amp max). Please see the wiring diagram furnished with the PRP (NOTE: PRP triac must have its mounting screw installed in order to dissipate heat). Electrical connections in the bilge and/or below the waterline should use heat shrink type butt splices.
ABYC standards are available from:
American Boat and Yacht Council 3069 Solomons Island Rd. Edgewater, MD 21036 Telephone: (410) 956-1050
The a/c unit must be connected to the ship’s bonding system to prevent corrosion due to stray electrical current or voltage. All pumps, metallic valves and
fittings in the seawater circuit that are isolated from the a/c unit by PVC or rubber hoses must be individually bonded to the vessels bonding system also. This will help eliminate any possibility of corrosion due to stray current or voltage.
FAILURE TO PROPERLY GROUND AND BOND THE SYSTEM WILL VOID WARRANTY!
3 Phase Notice
It is extremely important to insure that wiring and phase sequencing of a three phase power source is correct. Marine wiring standards call for power source phases L1, L2, and L3 to be color-coded BLACK, WHITE, and RED, respectively. These must be connected to the unit with the proper sequence, otherwise, it will not operate properly. If the wiring sequence is incorrect, the unit’s compressor (Scroll type only) and pump (if applicable) will run in the reverse direction at a significantly in­creased noise level.
Field wiring must comply with ABYC electrical codes. Power to the unit must be within the operating voltage range indicated on the data plate. Properly sized fuses or HACR circuit breakers must be installed for branch circuit protection. See data plate for maximum fuse/circuit breaker size (mfs) and minimum circuit ampacity (mca). All units must be effectively grounded to minimize the hazard of electrical shock and personal injury.
The following are to be observed:
1. AC (alternating current) grounding (green wire) must be provided with the AC power conductors and connected to the ground terminal (marked “GRND”) at the AC power input terminal block of the unit(s), per ABYC standard E-8, or equivalent.
2. Connections between the vessel’s AC system ground­ing conductor (green wire) and the vessel’s DC (Direct Current) negative or bonding system should be made as part of the vessel’s wiring, per ABYC standard E-9, or equivalent.
3. When servicing or replacing existing equipment that contains a chassis-mounted ground stud, the service person or installer must check the vessel’s wiring for the existence of the connection required in item 2 above.
Manual Control Panel (MCP) Installation
The MCP should be located within cap tube length of the a/c unit. The 3 knob MCP is configured either vertically (shown) or horizontally. The cut out size is 2.5" by 7.0", see MCP (Figure 6) for orientation. Once the cut out is made, carefully uncoil the copper cap tube with return air sensor (copper bulb) and route the control wires and cap tube through the hole and back to the a/c unit
caution not to kink the cap tube
sensor into the clips provided with the Vector Compact unit. If the return air sensor cannot be mounted on the evaporator coil, mount it behind the return air grille. The sensor must be mounted in the return air stream. Make electrical connections according to the wiring diagram found in the electric box and/or in this manual. See Figure 9.
. Mount the return air
using
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Installation Checklist
(Review prior to installation)
Note: Refer to the Elite and Passport I/O manuals for installation and operation of those digital controls.
Seawater Cooling System
Speed scoop located as far below the water line and
as close to the keel as possible
Electrical
The wiring diagram is located in the electrical box. If
that diagram is damaged or if you need a copy, please call Dometic with the unit part number, serial number, and wiring diagram number, all of which are located on the unit data plate.
All butt connections on pumps wire tightly crimped and
heat shrunk
AC power source installed and grounded/bonded in
accordance with ABYC standards
Shut off valve (sea cock) and speed scoop properly
sealed and tight
Seawater pump is at least one foot below water line
and securely mounted
Strainer mounted below pump with access to filter
Double/reversed stainless steel hose clamps on all
hose connections
Teflon tape on all threaded connections
Hose runs uphill from speed scoop and sea cock to
strainer, pump and a/c unit, then downhill (if possible) from a/c unit to overboard discharge
Water flowing freely from overboard discharge while
pump is running
Pump relay panel, if used, must have its own circuit
breaker sized for the pump (20 amp max)
All metal fittings should be bonded
Mounting
Not in engine room or bilge areas, must be sealed
away from exhaust or fumes
Control wires connected to terminal strip with captive
fork or ring terminals
Circuit breakers sized according to specifications on
the data plate label
Digital display cable is connected at both ends
Pump Relay Panel (if used) has a dedicated circuit
breaker sized for the pump but not to exceed 20 amps maximum.
Grilles and Ducting
Supply air grille mounted as high as possible
Return air grille mounted as low and as close to the
a/c unit as possible
Return air grille mounted away from bilge vapors or
exhaust fumes
Ducting is pulled taut, straight, smooth and properly
connected with no excess
Proper spacing allowed around unit
Attached to solid level platform with hold down clips
provided
Condensate drain routed aft and down hill to a sealed
sump (not bilge)
Blower rotated toward supply air grille
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OPERATION
Mechanical Control Panel (MCP) Operation
1. Ensure seawater intake ball valve (sea cock) is open.
2. Turn SYSTEM SWITCH control knob to OFF.
3. Turn on AC circuit breaker. If the seawater pump has its own circuit breaker, turn that on too. Or, if the pump is connected to a Pump Relay Panel (PRP), then turn on that circuit breaker also.
4. Turn the SYSTEM SWITCH control knob to START; this energizes the fan and seawater pump. Turn THERMOSTAT control knob to the coolest position by rotating fully clockwise. If system has reverse cycle, turn knob counter-clockwise for heat.
5. Check for a steady solid stream of seawater from the overboard discharge.
6. Turn FAN SPEED control knob clockwise to highest setting for cooling or counter-clockwise for heating.
7. Verify that the fan is running and that there is steady airflow out of the supply air grille.
8. Turn the SYSTEM SWITCH to RUN; this will start the compressor. The indicator light on the control will illuminate.
Quick Start Operations Checklist
Ensure seawater intake ball valve (sea cock) is open.
Turn on the a/c circuit breaker. If the seawater pump
has its own circuit breaker, turn that on.
Turn the system on.
Set the desired cabin temperature (set point).
Check for a steady solid stream of water from the
overboard discharge.
Verify that there is steady airflow out of the supply air
grille.
If the unit does not appear to be operating properly,
refer to troubleshooting guide lines.
Note: Do not turn the unit off and immediately turn it back on. Allow at least 30 seconds for refrigerant pressure equalization.
9. To set the thermostat, allow sufficient time for the unit to cool/heat the area to the desired temperature. When the area is sufficiently cooled/heated, turn the thermo­stat knob slowly toward the center position until it clicks once (the indicator light will turn off). The thermostat is now set to maintain a constant tempera­ture. While heating, if the ambient temperature is less than 50°F, set the FAN SPEED control knob to low for five to ten minutes until the unit begins to heat well, then increase the fan speed for more heat output and to prevent the system cycling on high pressure.
The thermostat on the MCP control panel serves to cycle the compressor on and off and provide an automatic changeover from cooling to heating (reverse cycle only) with a 3.5° differential. Rotating the thermostat to the left after it has been set for cooling will cause the unit to heat. If you rotate the thermostat to the right, the unit will cool. If the thermostat is left stationary after being set, the unit will cycle from cooling to neutral, or heating to neutral depending on the requirement.
Reverse cycle units have a reversing valve that must be energized periodically to keep the internal parts moving freely. To accomplish this, switch the A/C into HEAT for a few seconds once a month.
Note: Do not turn the unit off and immediately turn it back on. Wait at least 30 seconds.
L-2254 Operation
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