Reznor RCB060 Service Manual

Form O-MAPSIII&IV Cabinets A/B/C (Version B.4)



CQS

Obsoletes O-MAPSIII Cabinets A/B/C (Version B.3)

®

Operation / Maintenance / Service

Applies to: Cabinet Sizes A, B, and C

®

™

of MAPS®III Models RCB, RDB,

RDCB, RDDB, RECB, REDB and

MAPS®IV Models RCC, RDC,

RDCC, RDDC, RECC, REDC

P

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C

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CQS

E

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MAPS® Cabinet

Sizes A, B, and C

R-410A

Refrigerant

DANGER

This unit contains R-410A high pressure refrigerant. Hazards exist that could
result in personal injury or death. Installation, maintenance, and service should

only be performed by an HVAC technician qualied in R-410A refrigerant and

using proper tools and equipment. Due to much higher pressure of R-410A
refrigerant, DO NOT USE service equipment or tools designed for R22
refrigerant.

IMPORTANT: Do not release refrigerant to the atmosphere! If required service
procedures include the adding or removing of refrigerant, the service technician
must comply with all federal, state and local laws. The procedures discussed

in this manual should only be performed by a qualied HVAC technician.

Form O-MAPSIII&IV Cabinets A/B/C, P/N 257004R8, Page 1

Table of Contents

1.0 General ....................................................2-3

2.0 Maintenance Requirements ..................3-6

2.1 Maintenance Schedule.....................................4

2.2 Control Locations ............................................. 5

2.3 Cross-Reference of Models and

Cabinet Sizes A, B, and C ..............................6

3.0 Maintenance & Service Procedures ...6-21

3.1 Filters ..............................................................6

3.2 Drive Components ...........................................7

3.3 Condenser Fans...............................................8

3.4 Coil Maintenance .............................................8

3.5 Check Refrigerant Pressure & Temperatures

(subcooling and superheat) ............................. 9

3.6 Compressor Operation, Maintenance, and

Replacement.................................................. 11

3.7 Thermostatic Expansion Valves ..................... 19

3.9 Other Controls ................................................ 20

3.8 Optional Dampers and Damper Controls ....... 20

1.0 General

This booklet includes operation, maintenance, and service information for Cabinet
Sizes A, B, and C of the MAPS® III and MAPS® IV Models listed below. Before begin­ning any procedure, carefully review the information, paying particular attention to the
warnings. Handling of refrigerant should only be performed by a certied HVAC techni­cian with knowledge of the requirements of R-410A refrigerant and in compliance with
all codes and requirements of authorities having jurisdiction.

The instructions in this manual apply to the following MAPS® Models in Cabinet A, B,
and C Sizes and Model JHUP 250 and 300 duct furnace curb option.

4.0 Gas Heat Section Maintenance -

RDCB, RDCC, RDDB, RDDC .............21-30

4.1 Heat Exchanger, Burner, and Venter..............21

4.2 Heat Section Controls .................................... 25

4.3 Gas Train........................................................26

4.4 Other Gas Heat Section Controls / Sensors ..30

5.0 Electric Heat Section Maintenance -

RECB, RECC, REDB, REDC ..............30-31

6.0 Energy Recovery Module,

Option ER1 ..............................................31

7.0 Troubleshooting .................................32-39

7.1 Troubleshooting - Refrigeration (All Models) ..32

7.2 Compressor Digital Controller

Troubleshooting - all MAPS® IV Models.........33

7.3 Troubleshooting the Heat Section .................34

INDEX .............................................................40

NOTE: To conrm that this

booklet is applicable, see
list of Model and Cabinet
Sizes in Paragraph 2.3,
page 6.

Form O-MAPSIII&IV Cabinets A/B/C, Page 2

MAPS

Model

®

III MAPS®IV

RCB RCC

RDCB RDCC

RECB RECC

RDB RDC

RDDB RDDC

REDB REDC

JHUP

System Description (MAPS®III models have
staged cooling; MAPS®IV models have modulating
cooling.)

Makeup Air Cooling Packaged System, 1500-9000
CFM

Makeup Air Cooling Packaged System, 1500-9000
CFM, with Gas Heat Section (100-700 MBH)

Makeup Air Cooling Packaged System, 1500-9000
CFM, with Electric Heat Section (10- 88 kw)

Makeup Air Cooling and Re-heat Pump Reheat Cycle
Packaged System, 1500-9000 CFM

Makeup Air Cooling and Re-heat Pump Reheat Cycle
Packaged System, 1500-9000 CFM, with a Gas Heat
Section (100-700 MBH)

Makeup Air Cooling and Re-heat Pump Reheat Cycle
Packaged System, 1500-9000 CFM, with Electric Heat
Section (10 - 88 kw)

Optional Curb Section with 250 or 300 MBH Gas-Fired
Duct Furnace installed with a Model RDCB, RDCC,
RDDB or RDDC with a Size 250 or 700 Heat Section to
provide 500 or 1000 MBH heating

Denitions of Hazard

Intensity Levels used
in this Manual

There are warning labels on the unit and throughout this manual. For your safety,
comply with all warnings during installation, operation, and service of this system. See

denitions of Hazard Intensity Levels of warnings below.

HAZARD INTENSITY LEVELS

1. DANGER: Failure to comply will result in severe personal
injury or death and/or property damage.

2. WARNING: Failure to comply could result in severe
personal injury or death and/or property damage.

3. CAUTION: Failure to comply could result in minor personal
injury and/or property damage.

2.0 Maintenance
Requirements

To ensure long life and satisfactory performance, a system that is operating under nor­mal conditions should be inspected according to the Maintenance Schedule in Para­graph 2.1. If in an area where an unusual amount of dust or soot or other impurities are
present in the air, more frequent inspection is recommended.

Refer to the illustration in FIGURE 1 and follow the instructions in the referenced para­graphs to maintain this equipment. Maintenance requirements apply to all Models and
Sizes unless noted.

IMPORTANT: Do not release refrigerant to the
atmosphere! If required service procedures include the
adding or removing of refrigerant, the service technician
must comply with all federal, state and local laws. The
procedures discussed in this manual should only be

performed by a qualied HVAC technician familiar with

R-410A refrigerant.

WARNING

Lock power OFF before performing any maintenance
procedure (except where power is required such as
checking refrigerant pressure and temperature). Lock
disconnect switch in OFF position. If the system has a
gas heat section, when you turn off the power supply,
turn off the gas. See Hazard Levels above.

If replacement parts are required, use only factory-

authorized parts. For information, go to

www.ReznorHVAC.com or call (800)-695-1901.

Form O-MAPSIII&IV Cabinets A/B/C, P/N 257004R8, Page 3

2.0 Maintenance
Requirements
(cont'd)

2.1 Maintenance

Schedule

Important NOTE:

If equipped with an
optional energy recovery
module, refer to Form
I-MAPSIII&IV-ER
for enthalpy wheel
maintenance instructions

Monthly

□ Inspect lters; clean or replace as needed. See Paragraph 3.1.

□ Inspect the condensate drain; clean as needed. For information, see the

installation manual, Form I-MAPSIII&IV, Paragraph 6.2.

Semi-Annually

□ Inspect the unit blower and belts. Check belts for tension, wear, and alignment.

Adjust or replace as needed. Clean dirt from blower and motor. See Paragraph

3.2.

Annually

NOTE: Redo the cooling startup procedures when the cooling season begins. Refer

to Startup instructions in the installation manual, Form I-MAPSIII&IV, Paragraph 10.0.

All Models - Beginning of the cooling season or more frequently
in year-round cooling climate:

□ Inspect the wiring for any damaged wire. Replace damaged wiring.

□ Inspect the condensate drain pan. Clean the coil cabinet, clean the drain pan,

and ll the trap.

□ Inspect/clean condenser fans. See Paragraph 3.3.

□ Inspect/clean all coils. See Paragraph 3.4.

□ Check compressor operation. See Paragraph 3.6.

□ Check refrigerant pressure and temperatures (superheat and subcool). These

checks are done when the system is operating. See Paragraph 3.5.

Models RDCB, RDCC, RDDB, & RDDC with a gas heat section
(beginning of the heating season) - See Paragraph 4.0:

NOTE: A MAPS® B cabinet with 500 MBH of heat is a Size 250 gas heat section
plus an optional Model JHUP curb duct furnace. A MAPS® C cabinet with 1000
MBH of heat is a Size 700 gas heat section plus an optional Model JHUP curb duct
furnace. The same maintenance procedures apply to the duct furnaces.

□ Clean all dirt and grease from the combustion air openings and the venter

assembly.

□ Check the heat exchanger, burner, and venter for scale, dust, or lint

accumulation. Clean as needed.

□ Check the gas valves to ensure that gas ow is being shutoff completely.

Models RECB, RECC, REDB, & REDC with an electric heat section
(beginning of the heating season) - See Paragraph 5.0:

Form O-MAPSIII&IV Cabinets A/B/C, Page 4

□ Check wiring connections.

□ Check the heat section and elements for dust or lint accumulation. Carefully

clean as needed.

2.2 Control Locations

Controller

Display

(BacView)

IQ

Controller

Reheat

Board

Combustion

Air Proving

Switch

(RDCB/RDCC/

RDDB/RDDC)

Air
Proving
Switch

Power Supply

Ignition

Board

(RDCB/RDCC/

RDDB/RDDC)

Relay or
Sequencer
(RDCB/RDCC/
RDDB/RDDC)

Control

Expander

Option BHB6

Dirty Filter
Switch or
Differential
Pressure
Gauge

Low Voltage Panel - Cabinet C

Optional
Control
Block(s)

FIGURE 1 - Showing Access (panels removed) and High and Low Voltage Control Locations
(including control options)

Condenser Section

Compressors

Tubing
Access

Heat Section

(Gas illustrated)

High Voltage Panels

Cabinets A & B

Digital Controller

- MAPS IV only

Control

Transformers

Contactor,

Condenser Fan

Contactor,

Compressor A

Fuse & Fuse

Holder

Contactor,

Compressor B
Contactor, Compressor C
(below “B”, behind the transformer)

Cabinet C

Contactor,

Compressor B

Optional

Transformer

Control

Transformers

Digital Controller

- MAPS IV only

Fuse & Fuse

Holder

Contactor, Compressor DH

Phase Monitor or Motor Saver

Dampers

Blower Section
with Bottom Discharge

Two Low Voltage Panels ­A&B Cabinets (top right)

or Low Voltage Panel -

C Cabinet (bottom right)

Phase Monitor
or Motor Saver

Distribution
Blocks

Grounding
Lug

Contactor or
Starter and
Overload,
Blower Motor

Contactor,
Compressor DH

Optional Transformer

Contactor, Compressor A

Contactor,
Condenser Fan

Contactor,
Compressor C

Contactor or
Starter and
Overload,
Blower Motor
Distribution
Blocks
Grounding
Lug

Optional Transformer

Slide-out
Filter Rack

Reheat

Compressor

Evaporator Coil
Section (with slide
out drain pan)

Primary Low Voltage Layout - Cabinets A & B

Controller

Display

(BacView)

IQ

Controller

Optional

Plugin Card

Optional

Differential

Pressure

Switch

Combustion

Air Proving

Switch

(RDCB/RDCC/

RDDB/RDDC)

Air Proving

Switch

Venter Motor

Capacitor

(RDCB/RDCC/

RDDB/RDDC)

Secondary Low
Voltage Layout -

Cabinets A & B

Optional

Control

Expander

Optional

Reheat

Board

Sequencer
(RDCB/RDCC/
RDDB/RDDC)

Ignition
Board
(RDCB/RDCC/
RDDB/RDDC)

Optional
Control
Block(s)

Power
Supply

Form O-MAPSIII&IV Cabinets A/B/C, P/N 257004R8, Page 5

2.0 Maintenance Requirements (cont'd)

2.3 Cross-Reference of Models and Cabinet Sizes A, B, and C

DX Cooling
Models RCB
and RCC and
DX with Reheat
Models RDB
and RDC

Model

Model

RCB

RCC

060

078 --

090

118 120

136 --

160

186 --

200

190

216 --

298

410

Model

Model

RDB

RDC

084

102 --

114

142 144

162 --

184

-- 196

210 --

222 --

224 --

236

-- 257

248

262

272 --

288 --

354

370

468

482

3.0 Maintenance
and Service
Procedures

Cabinet Size A B C

Model Sizes 060/078/084/102 090/114/11//120/136/142/144/162 All Cabinet B All Cabinet C

Filter Description Opt Qty Size P/N Qty Size P/N Qty Size P/N Qty Size P/N

2” Pleated Disposable AW 11 1 20x25x2 104113

4” Pleated Disposable,
MERV 8

4” Pleated Disposable,
MERV 13

2” Permanent Aluminum AW9 1 20x25x2 101623

4” Permanent Aluminum AW20 2 20x25x2 101623

Model RDCB, RDDB, RDCC, and RDDC by Cabinet Size
and Gas Heat Section Size

Model

Model

RDCB

RDCC

-100 -150 -200 -250 -300 -400 -500 -600 -700 -800 -1000

060

Cabinet

Cabinet

078 --

Size

118 120

136 --

186 --

A

216 --

B

Model

RDDB

C

102 --

142 144

Size

162 --

-- 196

A

210 -­222 --

224 --

-- 257

B

272 -­288 --

* A MAPS® B Cabinet with 500 mbh of gas heat is a Size 250 mbh heat section plus an Option JH25 curb with a 250 mbh

C

duct furnace.

A A A -- -- -- -- -- -- -- --

A A A B B B* -- -- -- --

090

A A A B B B* -- -- -- --

A A A B B B* -- -- -- --

A A A B B B* -- -- -- --

160

-- -- -- B B B* -- -- -- --

-- -- -- B B B* -- -- -- --

200

-- -- -- B B B* -- -- -- --

190

-- -- -- -- -- C C C C -- C**

-- -- -- -- -- C C C C -- C**

298

-- -- -- -- -- C C C C -- C**

410

-- -- -- -- -- C C C C -- C**

Model

RDDC

-100 -150 -200 -250 -300 -400 -500 -600 -700 -800 -1000

084

A A A -- -- -- -- -- -- -- -­A A A B B -- -- -- -- -- --

114

A A A B B -- -- -- -- -- --

A A A B B -- -- -- -- -- --

-- A A B B -- -- -- -- -- --

184

-- -- -- B B -- -- -- -- -- --

-- -- -- B B -- -- -- -- -- --

-- -- -- B B -- -- -- -- -- --

-- -- -- B B -- -- -- -- -- --

-- -- -- B B -- -- -- -- -- --

236

-- -- -- B B -- -- -- -- -- --

-- -- -- B B -- -- -- -- -- --

248

-- -- -- -- -- C C C C -- C**

262

-- -- -- -- -- C C C C -- C**

-- -- -- -- -- C C C C -- C**

-- -- -- -- -- C C C C -- C**

354

-- -- -- -- -- C C C C -- C**

370

-- -- -- -- -- C C C C -- C**

468

-- -- -- -- -- C C C C -- C**

482

-- -- -- -- -- C C C C -- C**

Gas Heat Section Size

Gas Heat Section Size

Model RECB, REDB, RECC, and REDC by Electric Heat Module
and Cabinet Size

Model
RECB

060

078 --

090
118 120
136 --

160
186 --

200

190
216 --

298

410

Model
REDB

084
102 --

114
142 144
162 --

184

-- 196
210 -­222 -­224 --

236

-- 257

248

262
272 -­288 --

354

370

468

482

Model
RECC

-10S -15S -20S -24S -15 -20 -25 -30 -35 -39 -50 -60 -75 -88
A A A A A A A A A A -- -- -- --

-- A A A A B A A B A B B B --

-- A A A A B A A B A B B B B

-- A A A A B A A B A B B B B

-- A A A A B A A B A B B B B

-- -- -- -- B B B B B B B B B B

-- -- -- -- B B B B B B B B B B

-- -- -- -- -- B B B B B B B B B

-- -- -- -- -- -- -- -- -- C C C C C

-- -- -- -- -- -- -- -- -- C C C C C

-- -- -- -- -- -- -- -- -- C C C C C

-- -- -- -- -- -- -- -- -- C C C C C

Model
REDC

-10S -15S -20S -24S -15 -20 -25 -30 -35 -39 -50 -60 -75 -88
A A A A A B A A B A B B B --

-- A A A A B A A B A B B B B

-- A A A A B A A B A B B B B

-- A A A A B A A B A B B B B

-- -- -- -- A B A A B A B B B B

-- -- -- -- B B B B B B B B B B

-- -- -- -- -- B B B B B B B B B

-- -- -- -- -- B B B B B B B B B

-- -- -- -- -- B B B B B B B B B

-- -- -- -- -- B B B B B B B B B

-- -- -- -- -- B B B B B B B B B

-- -- -- -- -- B B B B B B B B B

-- -- -- -- -- -- -- -- -- C C C C C

-- -- -- -- -- -- -- -- -- C C C C C

-- -- -- -- -- -- -- -- -- C C C C C

-- -- -- -- -- -- -- -- -- C C C C C

-- -- -- -- -- -- -- -- -- C C C C C

-- -- -- -- -- -- -- -- -- C C C C C

-- -- -- -- -- -- -- -- -- C C C C C

-- -- -- -- -- -- -- -- -- C C C C C

Electric Heat Section

Electric Heat Section

** A MAPS® C Cabinet with 1000 mbh of gas heat is a Size 700 mbh heat section plus an Option JH30 curb with a 300
mbh duct furnace.

3.1 Filters

The lter section is equipped with a slide out lter rack and 2 or 4 inch, pleated dispos­able or permanent aluminum lters. To remove lters, open the door and slide lters
out. Replacement lters are listed in the table below. Do not use any other type of
lters.

AW21 1 20x25x4 205791

AW24 1 20x25x4 256663

If equipped with permanent aluminum lters, remove the lters, wash, rinse, allow to

dry, and slide them back in the cabinet.

If equipped with pleated disposable lters, replace dirty lters. Exposure to humid
makeup air can accelerate lter degradation. Systems with disposable lters require
more frequent lter inspection.

2 16x20x2 104110
2 20x20x2 104111
2 16x20x4 211127
2 20x20x4 205790
2 16x20x4 256665
2 20x20x4 256662
2 16x20x2 101620
2 20x20x2 101621
4 16x20x2 101620
4 20x20x2 101621

4 20x25x2 104113 6 20x25x2 104113

4 20x25x4 205791 6 20x25x4 205791

4 20x25x4 256663 6 20x25x4 256663

4 20x25x4 101623 6 20x25x2 101623

8 20x25x2 101623 12 20x25x2 101623

Dirty Filter Switch
(Options BE16 and
BE18)

If equipped with a dirty lter switch or gauge, check the condition of the sensing tubes

to be sure that they are not blocked. Check the wiring connections. To set a new switch
(Option BE18), see Installation Form I-MAPSIII&IV, Paragraph 8.3, Replacement
switch is P/N 105507.

Form O-MAPSIII&IV Cabinets A/B/C, Page 6

Filter

Clamp

Filter

Filter

Wing Screw,

P/N 205707,

and Retainer,

P/N 205709

(2 each)

Filter

Filter

Filter Clamps attach
with Wing Screws
P/N 205707

Filter

16x20x1

Filter

16x20x1

Filter

16x20x1

Filter

16x25x1

Filter

16x25x1

Filter

16x25x1

Filter

16x20x1

Filter

16x20x1

Filter

16x20x1

Inlet View













Permanent Filters in
the Outside Air Hood

If equipped with an outside air hood, there are 1" permanent, aluminum lters at the
entrance of the hood. The lters act as a moisture eliminator and bird screen. See FIG-
URE 2A or 2B. When inspecting the inlet air lters, inspect the outside air hood lters.
If cleaning is needed, remove the lters, clean, rinse, dry and re-install.

NOTE: If it is more convenient to keep an extra clean set of lters, lter sizes and part numbers are shown in the illustration.

FIGURE 2A -
Removing Filters
from Outside
Air Hood

1" Permanent
Aluminum Filters
for Outside Air

Cabinet Sizes A and B with Option AS16
Outside Air Hood

(Does not apply if
system includes
Option PE
power exhaust;
see below.)

All Cabinet Size C with
either Outside Air Hood
Option AS16 or AS19

Hood are listed by
Cabinet Size A, B, or C
(see cross-reference, page 6)

*A - (4) 16 x 20, P/N 101607
*B - (4) 16 x 25, P/N 101609

C - (3) 16 x 25, P/N 101609;

(6) 16 x 20, P/N 101607

* Apply only to Cabinet
Size A and B with outside

air hood Option AS16

.

Instructions: Remove lters by loosening the wing screws and sliding the lter

clamp(s). Clean with soap and water, allow to dry, and replace. If it is more convenient

to keep an extra clean set of lters, quantities, lter sizes, and part numbers are listed.

FIGURE 2B - Removing Filters from Option AS19 Outside Air
Hood Installed on a Cabinet Size A or B with power exhaust
Option PE1 or PE2

Instructions: 1) Remove the four screws as illustrated. Lower the tray.; 2) Pull out
lters. Clean with soap and water. Allow to dry.; 3) Slide clean dry lters into tray.;

4) Re-position tray and replace screws.
1" Aluminum Filters: **A - (4) 18 x 20, P/N 194903; **B - (4) 20 x 25, P/N 101610

** Apply only to Cabinet Size A and B with outside air hood Option AS19.

Filters in an Optional
Energy Recovery
Module

*See cross-reference of
MAPS® Models by Cabinet
Size A, B, or C on page 6.

3.2 Drive
Components

CAUTION: If the
blower is unused
for more than three
months, bearings

with a grease tting

should be purged
with new grease

prior to startup.

If equipped with an energy recovery module (Option ER1A, ER1B, or ER1C), check

both inlet and exhaust lters. Replace as needed.

Cabinet

Size *

A Pleated 20x25x2 2 104113 Pleated 20x25x2 2 104113

B

C

Inlet Air Filters (Merv 8) Exhaust Air Filters (Merv 8)

Filter Type & Size Qty P/N Filter Type & Size Qty P/N

Pleated 16x25x2 2 104112 Pleated 16x25x2 2 104112
Pleated 12x25x2 2 114320 Pleated 12x25x2 2 114320
Pleated 16x25x2 2 104112 Pleated 16x25x2 2 104112
Pleated 20x25x2 2 104113 Pleated 20x25x2 2 104113
Pleated 16x16x2 1 104109 Pleated 16x16x2 1 104109
Pleated 16x20x2 1 104110 Pleated 16x20x2 1 104110

Bearings - Bearings with a grease tting should be lubricated twice a year with a high

temperature, moisture-resistant grease. (Type NLGI-1 or -2 standard grease is recom-

mended.) Be sure to clean the grease tting before adding grease. Add grease with a

handgun until a slight bead of grease forms at the seal. Be careful not to unseat the
seal by over lubricating. NOTE: If unusual environmental conditions exist (tempera­tures below 32°F or above 200°F; moisture; or contaminants), more frequent lubrica­tion is required.

Setscrews - Check all of the setscrews (bearing/blower hubs and pulleys). Torque pul­ley setscrews a minimum of 110 in-lb to 130 in-lb maximum.

A bearing hub setscrew for a 1-3/8" to 1-3/4" shaft requires a 5/16" socket and a tight­ening torque of 165 in-lbs.

Belts - Check belt for proper tension and wear. If needed, follow instructions to adjust
belt tension. Replace worn belts.

Form O-MAPSIII&IV Cabinets A/B/C, P/N 257004R8, Page 7

2-1/2” (63.5mm)

Fan and Motor Assembly
showing Fan Blade Position

Cross-section of Installed Fan and Motor
Assembly showing Cabinet Top

1.76” (44.7mm)

Top of Fan Blade

to Top of the

Cabinet Top Panel

Fan rotation is
clockwise.

3.0 Maintenance
and Service
Procedures
(cont'd)

3.2 Drive
Components
Cont'd)

Belts (cont'd) - Blower systems are equipped with either Power Twist Plus

blower belt or a solid belt. The linked belts are designed in sections allowing for easy
sizing and adjustment. The belt is sized at the factory for the proper tension. If the belt
needs adjustment, the recommended method of shortening the belt length is to count
the number of links and remove one link for every 24. (A link is made up of two joining
sections of belt. For easier removal of links, turn the belt inside out. But be sure to turn
it back before installing.)

If equipped with a solid belt, adjust the belt tension by turning the adjusting screw on
the motor base until the belt can be depressed 1/2" (13mm) on each side. After correct
tension is achieved, re-tighten the locknut on the adjustment screw.

Proper belt tension is important to the long life of the belt and motor.
Be sure belts are aligned in the pulleys. If a belt is removed or replaced, be sure the

directional arrows on the belt match the drive rotation.
Motor and Blower - Inspect the motor mounts periodically. Remove dust and dirt accu-

mulation from the motor and wheel.
The blower has cast iron, pillowblock, sealed bearings. Under most operating condi-

tions, re-lubrication is unnecessary. If lubrication is required, use a lubricant compat­ible to Shell Alvania #2 (lithium base - Grade 2). Operating temperature range is -30
to 230°F.

If any drive parts need to be replaced, use only factory-authorized replacements
designed for the application.

®

linked

3.3 Condenser Fans

FIGURE 3 -
Condenser
Fan Assembly
Dimensions
and Rotation

3.4 Coil
Maintenance

Condenser
Coil Cleaning
Instructions:

Form O-MAPSIII&IV Cabinets A/B/C, Page 8

Depending on the size, there are two, three, or four fans in the condenser section. If
parts need to be replaced, use only factory authorized replacement parts. See FIGURE
3 for assembled dimensions and proper fan rotation.

The MAPS® cooling system is equipped with space-saving MACROCHANNEL
Inspect all cooling system coils at the beginning of the cooling season or more often if
needed. Follow the cleaning instructions below. If additional cleaning is required or if a
coil must be removed for any reason, consult the factory. Be prepared to provide rating

plate and specic installation information.

Condensing Coil Access - The condensing coils are visible on the side of the unit
(below the condenser fans). For additional access for inspection and maintenance,
remove the tubing access panel (See FIGURE 1, page 5.).

1. Verify that the electrical power has been turned off and the disconnect switch locked.

2. Use a soft brush to remove any dirt and debris from the coils.

3. Spray with cold or warm (not hot) water and a cleaning solution (non-acid based coil

4. When clean, rinse with cool, clean water.

Evaporator Coil Access - The evaporative coils can be accessed by opening the coil
cabinet door.

Inspect coils for debris, dirt, grease, lint, pollen, mold, or any element which would

obstruct heat transfer or airow. Inspect coils and tubing for physical damage. Inspect

®

coils.

cleaner is recommended). Due to possible damage to the coil, DO NOT use high
pressure spray.

feeders, piping connections, coil headers, and return bends for signs of fatigue, rub­bing, and physical damage.

Clean the coils annually, or more often if needed. Use the proper tools and follow the
instructions carefully to avoid damaging the coil. Use of a non-acid based coil cleaner is
recommended. Due to possible damage to the coil, DO NOT use high pressure spray.

Evaporator
Coil Cleaning
Instructions:

3.5 Check
Refrigerant
Pressure and
Temperatures
(subcooling
and superheat)

1. Verify that the electrical power has been turned off and the disconnect switch
locked.

2. Open the access panels.

3. Use a soft brush to remove any dirt and debris from both sides of a coil.

4. Spray with cold or warm (not hot) water and a cleaning solution (non-acid based
coil cleaner is recommended). Due to possible damage to the coil, DO NOT use

high pressure spray. First spray the leaving airow side, then the inlet airow side.

As much as possible, spray the solution perpendicular to the face of the coil.
Follow the instructions on the cleaning solution. When cleaning process is

complete, rinse both sides with cool, clean water.

DANGER

These refrigeration circuits are high pressure systems.
Hazards exist that could result in personal injury or death.
Removal, installation, and service of this scroll compressor

must be performed by a technician qualied in R-410A

refrigerant. DO NOT USE service equipment or tools designed
for R22 refrigerant. See Hazard Levels, page 3.

Two important requirements before checking superheat and subcooling:

1) This unit has fully intertwined refrigerant circuits and each circuit MUST be isolated before measuring its

temperature. Another active circuit will inuence the reading and make it impossible to determine accurate superheat

and subcooling.

2) If the circuit is equipped with an optional hot gas bypass valve, the valve must be disabled before measuring
superheat and subcooling. Method of disabling depends on the model and date of manufacture.

All MAPS®IV Models & any MAPS®III Models with a shutoff valve in the line between the compressor discharge and
the hot gas bypass valve - Locate the shutoff valve. Disable the hot gas bypass valve by closing the shutoff valve.
When measurements are complete, be sure to open the valve.

MAPS®III Models without a shutoff valve in the line between the compressor discharge and the hot gas bypass valve

- Disable the hot gas bypass valve by removing the cover and adjusting the spring tension counterclockwise until the
spring tension is relieved. Count and record the number of turns required so that you can return the bypass valve
to its original setting. To check setting, refer to Paragraph 3.9.5.

Check SUBCOOLING

Measure and record temperature and pressure of the liquid line at the condenser coil outlet.

STEP 1) Record Measurements: Temperature = ________°F (°C) and Pressure = ________ psig

STEP 2) From Temperature/Pressure Conversion Chart (page 10), convert Measured Pressure (STEP 1) to

________°F (°C)

STEP 3) Subtract Measured Temperature (STEP 1) from Temperature from Conversion Chart (STEP 2)

________°F (°C) - ________°F (°C) = ________°F (°C) degrees of Subcooling

Recommended subcooling with outdoor temperature range of 70 to 95°F (21 to 35°C)

is 10 to 12 degrees F (5.6 to 6.7 degrees C).

Too much subcooling indicates a refrigerant overcharge. To reduce the subcooling, remove excess refriger-

ant. Too little subcooling indicates a refrigerant undercharge. To increase subcooling, slowly add R-410A
refrigerant.

Form O-MAPSIII&IV Cabinets A/B/C, P/N 257004R8, Page 9

3.0 Maintenance and Service Procedures (cont'd)

3.5 Check
Refrigerant
Pressure and
Temperatures
(cont'd)

WARNING

Do not release refrigerant to the atmosphere. When adding or

removing refrigerant, the qualied technician must comply

with all national, state/province, and local laws.

Determine SUPERHEAT

Measure and record temperature (insulate probe from surrounding air temperature)
and pressure in the suction line at the compressor inlet.

STEP 1) Record Measurements: Temperature = _______°F (°C) and

Pressure = _______ psig

STEP 2) From Temperature/Pressure Conversion Chart (below), convert

Measured Pressure (STEP 1) to ________°F (°C)

STEP 3) Subtract Measured Temperature (STEP 1) from Temperature from

Conversion Table (STEP 2)

________°F (°C) - ________°F (°C) = ________°F (°C) degrees of

Superheat

Recommended superheat range is 8 to 12 degrees F (4.5 to 6.7
degrees C).

Typically, too much superheat indicates that the evaporator coil is undercharged.
Too little superheat typically indicates that the evaporator coil is overcharged and

may potentially ood liquid refrigerant to the compressor. To reduce the superheat,

adjust the thermal expansion valve by turning the adjusting stem counterclock­wise. To increase the superheat, adjust the thermal expansion valve by turning the
adjusting stem clockwise.

Temperature/Pressure Conversion Chart

R-410A Refrigerant R-410A Refrigerant R-410A Refrigerant R-410A Refrigerant R-410A Refrigerant

Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature

PSI °F °C PSI °F °C PSI °F °C PSI °F °C PSI °F °C

1.8 -55 -48.3 49.5 1 -17.2 77.0 19 -7.2 112.2 37 2.8 218.2 75 23.9

4.3 -50 -45.6 50.9 2 -16.7 78.7 20 -6.7 114.4 38 3.3 235.9 80 26.7

7.0 -45 -42.8 52.2 3 -16.1 80.5 21 -6.1 116.7 39 3.9 254.6 85 29.4

10.1 -40 -40.0 53.6 4 -15.6 82.3 22 -5.6 118.9 40 4.4 274.3 90 32.2

13.5 -35 -37.2 55.0 5 -15.0 84.1 23 -5.0 121.2 41 5.0 295.0 95 35.0

17.2 -30 -34.4 56.4 6 -14.4 85.9 24 -4.4 123.6 42 5.6 316.9 100 37.8

21.4 -25 -31.7 57.9 7 -13.9 87.8 25 -3.9 125.9 43 6.1 339.9 105 40.6

25.9 -20 -28.9 59.3 8 -13.3 89.7 26 -3.3 128.3 44 6.7 364.1 11 0 43.3

27.8 -18 -27.8 60.8 9 -12.8 91.6 27 -2.8 130.7 45 7.2 389.6 11 5 46.1

29.7 -16 -26.7 62.3 10 -12.2 93.5 28 -2.2 133.2 46 7.8 416.4 120 48.9

31.8 -14 -25.6 63.9 11 -11.7 95.5 29 -1.7 135.6 47 8.3 444.5 125 51.7

33.9 -12 -24.4 65.4 12 -11.1 97.5 30 -1.1 138.2 48 8.9 474.0 130 54.4

36.1 -10 -23.3 67.0 13 -10.6 99.5 31 -0.6 140.7 49 9.4 505.0 135 57.2

38.4 -8 -22.2 68.6 14 -10.0 101.6 32 0.0 143.3 50 10.0 537.6 140 60.0

40.7 -6 -21.1 70.2 15 -9.4 103.6 33 0.6 156.6 55 12.8 571.7 145 62.8

43.1 -4 -20.0 71.9 16 -8.9 105.7 34 1.1 170.7 60 15.6 607.6 150 65.6

45.6 -2 -18.9 73.5 17 -8.3 107.9 35 1.7 185.7 65 18.3 645.2 155 68.3

48.2 0 -17.8 75.2 18 -7.8 110.0 36 2.2 201.5 70 21.1

Form O-MAPSIII&IV Cabinets A/B/C, Page 10

3.6 Compressor

Compressor B

Compressor C

Compressor A

Compressor

Dh (Reheat)

Operation,
Maintenance,
and
Replacement

DANGER

The refrigeration circuits are high pressure systems.
Hazards exist that could result in personal injury or death. It
is therefore required that the removal and installation of this

scroll compressor be performed by a technician qualied in

R-410A refrigerant. See Hazard Levels, page 3.

DANGER

Never use oxygen to pressurize a refrigeration system. Oxygen
can explode on contact with oil and could result in personal injury
or death. When using high pressure gas such as nitrogen for
this purpose, ALWAYS USE A PRESSURE REGULATOR that can
control the pressure down to 1 or 2 psig. Failure to use a regulator
will result in extremely high pressure which could exceed the
burst pressure of the compressor or other system components
and result in personal injury or death. See Hazard Levels, page 3.

WARNINGS

For your safety, wear eye protection, gloves, and protective
clothing when handling refrigerant and oil and when brazing.

Have a re extinguisher nearby. See Hazard Levels, page 3.

Compressor Staging
(Cooling) - applies to
all MAPS®III Models

Each MAPS®III system leaves the factory with the compressor staging sequence
shown here for that Model and Size. The compressor will start based upon a call for
cooling to maintain the discharge air temperature setpoint. There is a minimum 240
second ON and OFF time for each stage (not compressor).

FIGURE 4 - Identication of

Compressors by Circuit and
Staging for MAPS®III Models

Cabinet

Size

A

A or B

B

C

Cooling

Size

(RCB)

060
078
090

118

136

160 184 B A A+B A+B+C --

186

200

190

216

298

410

Cooling/

Reheat Size

(RDB)

084 B A A+B -- -­102 B A A+B -- -­114 B A A+B -- -­142 B A A+B -- -­162 B A A+B -- --

210 A B A+C A+B A+B+C
222 A B A+C A+B A+B+C
224 A B A+B B+C A+B+C
236 A B A+B B+C A+B+C
248 A B A+B -- -­262 A B A+B -- -­272 B B+C A+B+C -- -­288 B B+C A+B+C -- -­354 B A+B B+C A+B+C -­370 B A+B B+C A+B+C -­468 B A+B A+B+C -- -­482 B A+B A+B+C -- --

Cooling Staging by Compressor

Circuit

1st 2nd 3rd 4th 5th

Compressor

NOTE: Staging listed by cooling only Models RCB/RDB also

applies to Models RDCB /RDDB with gas heat and Models RECB/
REDB with electric heat.

Form O-MAPSIII&IV Cabinets A/B/C, P/N 257004R8, Page 11

3.0 Maintenance/Service Procedures (cont'd)

Alarm Light
(Red LED) - See
Paragraph 7.2.

Compressor
Modualting
Solenoid Valve
Energized Light
(Yellow LED)

Power Light
(Green LED)

3.6 Compressor Operation, Maintenance, and Replacement (cont'd)

Compressors and Crankcase Heater P/N's by Voltage on MAPS®III Models

208-240/3/60 480/3/60 575/3/60

Compressor

Model P/N Model P/N Model P/N

ZP24K5E 235095 216434 ZP24K5E 235097 216436 ZP24K5E 235099 216437
ZP36K5E 235096 216398 ZP36K5E 235098 216400 ZP36K5E 235100 216401
ZP54K5E 235008 216398 ZP54K5E 235012 216400 ZP54K5E 235016 216401
ZP57K3E 216686 216398 ZP57K3E 216687 216400 ZP57K3E 216688 216401
ZP72KCE 235009 216398 ZP72KCE 235013 216400 ZP72KCE 235018 216401
ZP83KCE 216689 216398 ZP83KCE 216690 216400 ZP83KCE 216691 216401
ZP137KCE 235010 216398 ZP137KCE 235014 216404 ZP137KCE 235019 216405
ZPT144KCE 235011 216398 ZPT144KCE 235015 216400 ZPT144KCE 235020 216401
ZP154KCE 220260 216402 ZP154KCE 220261 216404 ZP154KCE 220262 216405

Crankcase
Heater P/N

Compressor

Crankcase
Heater P/N

Compressor

Crankcase
Heater P/N

Modulating Cooling -

®

MAPS

IV Models

MAPS®IV units are equipped with a modulating capacity compressor and a digital con-

troller to provide cooling modulation. The digital controller in the control compartment
(See FIGURE 1, page 5) is the electronic interface between the compressor and the

NOTE: To identify MAPS®IV
Models, see Paragraph 1.0.

system controller. The compressor controller is connected to the unit controller to pro­vide protection and diagnostics for modulating compressor operation.

After a compressor shutdown, a two-minute anti-short cycle timer in the compressor

controller delays the compressor restart. The unit controller has a ve-minute compres­sor on/off time. The delay times are concurrent so total delay time is ve minutes.

FIGURE 5 - Compressor Digital Controller
located in the control compartment
interfaces the modulating capacity
compressor with the unit controller.

LED
Color

Green Solid

Green Flashing Anti-short cycle timer is active

Yellow Solid

Red Not lit No abnormal operation alerts

NOTE: See Troubleshooting, Paragraph 7.2.

LED
State

Indicates

Power (24VAC present at power
terminals)

Unloader (Solenoid valve is

energized; compressor capacity is 0.)

Compressor and Crankcase Heater P/N's by Voltage on MAPS®IV Models

208-240/3/60 480/3/60 575/3/60

Compressor

Model P/N Model P/N Model P/N

ZP24K5E 235095 216434 ZP24K5E 235097 216436 ZP24K5E 235099 216437
ZP36K5E 235096 216394 ZP36K5E 235098 216396 ZP36K5E 235100 216397
ZP54K5E 235008 216394 ZP54K5E 235012 216396 ZP54K5E 235016 216397
ZP57K3E 216686 216398 ZP57K3E 216687 216400 ZP57K3E 216688 216401
ZP61KCE 261235 216398 ZP61KCE 261236 216400 ZP72KCE 235018 216401
*ZPD61KCE 261145 216398 *ZPD61KCE 261146 216400 ZP83KCE 216691 216401
ZP72KCE 235009 216398 ZP72KCE 235013 216400 *ZPD83KCE 261149 216401
ZP83KCE 216689 216398 ZP83KCE 216690 216400 ZP137KCE 235019 216405
*ZPD83KCE 261147 216398 *ZPD83KCE 261148 216400 *ZPD137KCE 261155 216405
ZP137KCE 235010 216402 ZP137KCE 235014 216404 *ZPD61KCE 268531 216401
*ZPD137KCE 261153 216402 *ZPD137KCE 261154 216404 ZP61KCE 268532 216401
ZP154KCE 220260 216402 ZP154KCE 220261 216404 *ZPDT14MCE 268533 216401
*ZPDT14MCE 262656 (2)216398 *ZPDT14MCE 262657 (2)216400 * Modulating capacity compressor

Form O-MAPSIII&IV Cabinets A/B/C, Page 12

Crankcase
Heater P/N

Compressor

Crankcase
Heater P/N

Compressor

Crankcase
Heater P/N