EZ Series GS Owner`s Manual
Contents
1. 21u04129 3 Ajquiassy xog 21129 3 I 33 ELECTRONIC BOARD DIAGNOSIS TEST Base Intellitemp Each unit has two built in tools to assist the technician in the troubleshooting of the entire system The first tool is the Continuous System Diagnostics and the second tool is the Automatic System Component Test 1 Continuous System Diagnostics The control incorporates continuous self diagnostic checking of several system parameters and reports the status by an LED blink code on the main board 1 2 3 4 Un plug or disconnect the power to the unit Gain access into the electric box on the chassis and locate the main board within Locate the LED labeled DIAGNOSTIC STATUS on the main board near the center of the board Reapply power to the unit wait approximately 10 seconds and the unit will enter its normal operating mode At this time the diagnostic indicator LED will blink repeatedly These blink codes will repeat approximately every 5 seconds with a delay between cycles and are readable as follows 0 blinks No power 1 blink 2 Normal 2 blinks IAT indoor air temperature probe failure check connection replace 3 blinks 2 OAT outdoor air temperature probe failure check connection replace 4 blinks Communications failure between boards 5 blinks Keypad failure stuck key or interconnect amp ribbon cable failure 6 blinks Remote thermostat input failure bad input combinatio2. Skip 247 WHEEL REPLACEMENT See Figure 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Make sure unit has been disconnected from the power source Unplug or disconnect at circuit breaker box fuse box as required Confirm that power is off at the unit Remove front decorative cabinet panel Remove front panel of chassis by removing all panel mounting screws on chassis side NOTE COMPLETE FAN DECK ASSEMBLY MUST BE REMOVED FOR SERVICE Remove two clamps one on each end of pan attached to coil end plates with screws Disconnect the drain hose at the drain pan Unplug motor wires from quick connector Remove thermostat bulb from the blower housing Press down on front of pan and pull forward Pan should slip off the locating brackets and be ready to continue servicing on a bench Remove three screws and orifice ring from side of blower housing Loosen wheel setscrew with allen torx wrench and slip off shaft Replace with new wheel Make sure vanes are in right direction for the airflow Tighten setscrew and re assemble fan deck assembly by reversing the above procedure making sure that rotation is correct and the wheel is centered in the housing when running Remount pan assembly into unit by inserting pan under evaporator coil making sure the rear of the pan is resting on the locating brackets Lift up the front and hold while attaching c
3. STARTUP CHECKUST Note Units are to be installed and checked for proper function by qualified service personnel ONLY Check the following 1 Check for proper voltage and correct receptacle wiring e 2 Filter clean and in 35 All panels in place Sheek IR BEER 4 Condenser coil inlet and outlet free of obstructions and is sealed to louver L 5 Unit is properly sealed in 6 Evaporator air inlet and outlet is free of obstructions and properly sealed O 7 Open manual gas shut off valve and check 8 Check for proper operation of cooling heating and fan see Page 15 9 Owner or operator instructed on control operation and routine 10 Work area clean and free of debris Optional Limited Warranty Programs Islandaire offers the following OPTIONAL Limited Warranty Program Call your sales representative for additional information on the following Optional Limited Five 5 year parts amp labor on entire unit 66
4. Island The perfect fit 22 Research Way East Setauket NY 11733 Toll Free 1 800 886 2759 Fax 631 471 2913 Website www islandaire com E Mail saleseislandaire com Manufacturer of Quality Air Conditioning and Heating Products 6140025 Rev H
5. DO NOT PUT HOLES THROUGH WALL SLEEVE BOTTOM 14 SLOPE DOWN TO THE OUTSIDE SURFACE OF FINISHED FLOOR OR CARPET 4 14 MIN PROJECTION BEYOND EXTERIOR WALL Figure 3 Wall Installation 233 1 2 MAXLONG SCREWS FOR SECURING ANGLES TO TOP AND SDES OF SLEEVE WIDOWOR WALL WORSE CAULK AL AROUND WALL SLEEVE CABINET FRONT REAR GRILE WAL SLEEVE ANGLES AND SCREWS BY INSTALLER E DONOT PUT HOLES THROUGH OR DRIVE SCREWS INTO WALL SLEEVE BOTTOM 1H SLOPE DOWN TO THE QUSE SUBBASE SURFACE OF FINISHED I 1 MIN PROJECTION BEYOND EXTERIOR WALL Figure 4 Panel Wall or Window Installation Sub Base Required 12 4 Connect gas supply line to valve located lower right front of the unit Figures 5 and 6 manual valve must be installer supplied either inside or just outside of the wall sleeve as appropriate per local codes and or ANSI Z223 1 or CAN CGA B149 An 18 24 inch listed gas hose flexible connector with 12 SAE female flare must be installer supplied for connection to the appliance 6 375 RECOMMENDED LOCATION 6 50 Figure 5 Gas Supply Entrance Top View cm GAS PIPE TO BE NOT HIGHER 22877 2 00 ABOVE FLOOR ELBOW RIGHT ON OF PIPE FROM FLOOR GAS SHUT OFF VALVE SUPPLIED BY INSTALLER UNIT HAS TO SLIDE
6. INSTALLING AIR DISCHARGE PACKAGE NOTE Recommended for use on models with remote thermostat Not recommended for models with built in thermostats This original package allows for distribution of air into an adjacent zone requiring a controlled temperature This assembly will discharge the conditioned air to either the right or left depending upon which end the end cap is placed See Figure 23 NOTE Modification to the factory supplied duct kit other than outlined herein will void the warranty Total overall length of duct kit not to exceed 10 feet 1 2 3 4 5 6 7 8 9 10 11 12 Installation when adaptor support brackets are mounted to finished wall See Figure 24 NOTE projection of wall sleeve into room cannot exceed 1 1 4 Remove the front panel assembly part 4080699 and remove enclosure channel item 6 part 4080698 Pull the chassis out of the sleeve Remove the grill item 18 part 6070046 from the unit Install the plenum item 2 part 1900127 on the unit using four black pan screws item 16 part 6060026 Pre assemble duct items 7 amp 8 parts 4080701 amp 4080702 shipped as 4080704 with end cap item 9 part 4080703 baffle item 4 part 2500188 and grill item 18 part 6070046 using the hardware shown End cap can be installed left or right depending on the requirement Install the long bracket item 1 part 1600152 to the wall See Figure 24 Top View Place the pre assembled parts see note 7
7. Install the long bracket item 1 part 1600152 with the short bracket item 2 part 1600210 using two long pan screws item 19 part 6060092 and two lock nuts item 17 part 6060034 Place the pre assembled parts see note 6 above so that when chassis is pushed back into the sleeve the plenum follows the track provided below duct bottom Mount the front panel assembly without enclosure channel item 5 part 4080698 Install the extension item 10 part 4080707 or the connectors as needed Air delivery baffle item 4 part 2500188 located under the discharge air grill is factory positioned to provide a 50 50 distribution of air into each zone By removing it and cutting along the scored line results in 60 40 air distribution Removing the baffle completely will result in 70 30 split Duct extensions are also available without the grill in the following sizes 60 part 4080780 43 125 part 4080709 and 10 5 part 4080991 56 Variable 1 70 6 94 5 Duct Exterior Wall 6 44 Wall Sleeve 16 34 4 50 Min Unit Enclosure Non structural 1 25 When brackets mounted to wall skirt 1 25 Min When brackets are mounted to wall sleeve Finished Floor Figure 26 Duct Kit Installed 57 Gas Unit Louver Installation Instructions Figure 27 1 Position louver through middle of sleeve and pull louver back against louver mounting brackets 2 Hold louver with one hand aga
8. W O GRILL GS2 10 500 14 4 6060019 SCREW 8 X 12 SELF 1 4 IN HEX HEAD 15 6 6060020 SCREW 8 X PHIL PAN 16 6 6060026 SCREW 8 X PHIL PAN BLACK 17 2 6060034 LOCK NUTS 18 2 6060040 SCREW 8 X 5 AB POINT SLOTTED HEX 19 2 6060092 SCREW 10 32 X 1 2 LONG PAN HEAD 20 1 6070046 GRILL JA CK HYD ROOM CABINET 21 1 WSGS2 WALL SLEEVE GS2 RECESSED METAL 39 500 31 500 S snort Figure 25 Duct 1 2 3 4 5 6 7 8 9 10 11 12 13 Installation when adaptor support brackets are mounted to wall sleeve See Figure 25 NOTE projection of wall sleeve must be over 1 1 4 Remove the front panel assembly part 4080699 and remove enclosure channel item 5 part 4080698 Pull the chassis out of the sleeve Remove the grill item 20 part 6070046 from the unit Install the plenum item 3 part 1900127 on the unit using four black pan screws item 16 part 6060026 Install the short bracket item 2 part 1600210 on the sleeve using two self tapping screws item 14 part 6060019 See Figure 25 Top View Pre assemble duct items 7 amp 8 parts 4080701 amp 4080702 shipped as 4080704 with end cap item 9 part 4080703 baffle item 4 part 2500188 and grill item 20 part 6070046 using the hardware shown End cap can be installed left or right depending on the requirement
9. Internal Control Failure Steady On Air flow Fault 1 Flash Flame with no call for Heat 2 Flashes Ignition Lockout 3 Flashes 28 THERMOSTAT FOR MECHANICAL CONTROLS 8 REPLACEMENT Before replacement of the thermostat it should thoroughly checked by qualified to determine true condition Make sure each unit is disconnected from power source by unplugging disconnecting switch or disconnect at incoming circuit breaker or fuse box Test for voltage before starting service Cycle the thermostat If a clicking sound is heard a continuity check should be made to determine that the electrical circuit has not broken down At one point continuity will be found between terminals 2 common and 1 on cooling circuit when knob is rotated clockwise and between terminals 2 and 3 when knob is rotated counter clockwise on heating circuit If room temperature is above 85 degrees at time of test it may be necessary to cool thermostat bulb in cool water below 75 degrees to allow thermostat to operate on heating circuit If thermostat does not function properly replace according to the following instructions 2 3 4 5 6 7 8 9 Remove decorative front panel and disconnect power Remove two screws located on the front of electric box top and rotate electric box top upwards Remove thermostat knob Locate thermostat mounting screws under the decorative operation plate near the thermostat c
10. achieved after the third attempt the appliance will enter a lockout mode Combustion airflow is continually monitored during an ignition sequence by the airflow switch If during the initial call for heat the airflow switch contacts are in the closed position for 30 seconds without an output to the combustion blower an airflow fault will be declared and the control will remain in this mode with the combustion blower off waiting for the airflow switch contacts to open If the pressure differential switch remains open for more than 30 seconds after the combustion blower is energized an airflow fault will be declared and the control will stay in this mode with the combustion blower on When proper airflow is detected from the pressure differential switch the control begins the prepurge period with normal ignition sequence as follows If the pressure differential signal is lost while the burner is firing the control will immediately de energize the gas valve and the combustion blower will remain on If the call for heat remains the control will wait for proper airflow to return the proper airflow is not detected after 30 seconds an airflow blower fault signal will flash at the LED If the proper airflow is detected at any time a normal ignition sequence will begin with the prepurge period The LED can be viewed without removing the unit from the wall by removing or tilting front cover forward and observing it through the clear view port loc
11. 34 FLAME SENSOR RING 6090143 LEFT GASKET COMBUSTION 6090145 COMB BASE FLANGE GASKET 6130050 PRESSURE DIFFERENTIAL TUBE 6130050 DRAIN TUBE BURNER ASSEMBLY 2500280 BURNER BKT ASSY GS2 6040259 BURNER INSERT ASSY GAS Figure 30 Combustion Burner Parts 61 EXPLODED VIEW ITEM PART NAME 1 1600XXX MOUNT GS2 G3 COMB BLOWER UNIVERSAL 2 6020XXX AIR BLOWER 3 6060024 SCREWS 4 6060034 LOCK NUTS 5 6090146 GASKET COMB AIR BKT 6 6090177 GASKET GS2 G3 BOTTOM COMB AIR NEW 7 6160XXX AIR RESTRICTOR e o 31 er Combustion Air Parts 62 EXPLODED VIEW QTY PART NAME 2 IMF BLOWER ASSY 1 6120028 BLWR WRAP IMF FANDECK MEDIUM 8 313 1 6120062 BLWR HOUSING IMF LEFT SIDE 1 6120063 BLWR HOUSING IMF RIGHT SIDE 1 1500062 DRAIN PAN METAL LONG ALU GS2 1 1600227 MOTOR MOUNT BRACKET IMF FANDECK STYLE 1 1700200 FAN DECK GS2 1 6020XXX MOTOR EVAPORATOR 14 6060024 SCREW 8 X 3 8 HEX SLOTTED 2 6120047 BLOWER WHEEL STD Figure 32 Fan Deck Parts 63 EXPLODED VIEW ITEM PART NAME 1 6160148 90 ELBOW 2 6160147 PIPE NIPPLE 3 6040XXX GAS VALVE 4 6090148 RUBBER BUSHING 5 6040XXX ORIFICE 6 6060024 FASTENER Figure 33 Gas Valve Parts 64 Date of Start Serial Address
12. 845 850 830 848 1135 1140 1123 1143 1572 1557 1614 EER 11 4 11 4 11 4 11 6 11 2 112 112 112 10 7 10 7 10 7 10 7 9 6 9 6 9 6 High 340 340 320 340 400 400 30 40 400 400 380 400 460 440 460 CFM Low Cool Heat 260 260 240 260 260 260 240 260 340 340 320 340 340 320 340 HEATING OPTIONS Available with any cooling unit Input BTUH Heat 12 000 12 000 12000 12 000 15 000 15 000 15 000 15 000 18 000 18 000 18 000 18 000 Output BTUH 10 200 10 200 10200 10 200 12 150 12 150 12 150 12 150 14 711 14 711 14711 14 711 Volts 115 208 230 277 115 208 230 277 115 208 230 277 Watts Heat 224 184 254 294 224 184 254 294 224 184 254 294 Thermal Efficiency 85 0 85 0 85 0 85 0 81 0 81 0 81 0 81 0 81 7 81 7 81 7 81 7 Amps Heat 2 2 1 0 1 3 1 2 2 2 1 0 1 3 1 2 2 2 1 0 1 3 1 2 This appliance is based sea level operation and need changed for operation up to 2 000 feet elevation For use in the USA de rate 496 per thousand feet above this elevation this appliance is approved in Canada for elevations of 0 4 500 feet 4 Electrical Ratings Voltage Amperage Configuration Number 115 208 230 208 230 277 208 230 8 3 INSTALATION Any safety screen or guard removed for servicing an appliance must be replaced prior to operating the appliance When installed in the appropriate wall sleeve this appliance has zero clearance to combustible construction The appliance and its ap
13. Islandaire Operating amp Manual for Direct Vent Gas Fired Packaged Terminal Thru Wall Air Conditioners EZ Series GS WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Table of Contents Page Contents Section 3 Unit Specifications 1 6 Installation 2 15 Operating Instructions 3 25 Servicing 4 50 Accessories 5 59 Replacement Parts 6 65 Start Up Checklist 7 THIS BOOK CONTAINS INSTRUCTIONS FOR INFORMATION AND OPERATIONS OF YOUR UNIT KEEP IN A SAFE PLACE FOR READY REFERENCE SHOULD YOU REQUIRE FURTHER INFORMATION CONTACT YOUR DEALER OR OUR TECHNICAL SUPPORT DEPARTMENT AT 1 800 886 2759 THE INFORMATION IN THIS MANUAL MUST BE FOLLOWED IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN VOID WA
14. L 31 6040261 FAN SWITCH 32 6040262 LIMIT SWITCH 33 6040 OVERLOAD 34 6070014 GRILL DISCHARGE KA BLACK 35 6080015 FILTER 16 7 x 30 x 3 32 36 6090059 GASKET GS HEAT EXCHANGER RT 37 6090060 GASKET GS HEAT EXCHANGER EXHAUST 38 6090146 AIR BKT 39 6110087 HEAT EXCHANGER 40 6120059 FAN BLADE 41 6160 CAPILLARY TUBE 42 6160XXX AIR RESTRICTOR 43 ELECTRICAL CONTROL BOX ASSEMBLY FAN DECK ASSEMBLY EXPLODED VIEW QTY PART NAME 1 1300549 ELECTRICAL BOX GS2 2 1300550 SWITCH PLT DIG5 5BUT GS2 1 4020067 CONTROL PLATE GSWM FIVE BUTTON 1 6030372 DIGITAL BRAIN BOARD DIG5GA BASE UNIT 1 6040038 THERMOSTAT 1 6040046 RELAY 1 6040081_ SWITCH 5 BUTTON 1 6040132 SWITCH ROCKER 1 6040156 IRANSFORMER 1 6040173 MEMBER INTELLITEMP 1 6040253 IGNITION CONTROL MODULE 1 6040255 PRESSURE DIFFERENTIAL SWITCH 1 6040370_ DIGITAL DISPLAY BOARD DIG5GA BASE 1 6040440 IGNITOR JUMP STARTER 1 6080025 THERMOSTAT KNOB 2 6130067 PLASTICS HEYCO WINDOW PLUG 1 6300587 WIRING DIAGRAM Figure 29 Electric Box Parts EXPLODED VIEW PART NAME 2500284 COMBUSTION BASE GS2 2500285 SIGHT GLASS COVER 4010095 GAS VALVE ASSEMBLY 6040254 FLAME SENSOR 6040XXX HOT SURFACE IGNITOR 6090133 IGNITOR O RING 60901
15. OVER ALL PIPING EXCEPT FINAL CONNECTION Figure 6 Gas Supply Entrance Front View STEP 5 Pressure test and purge gas piping according to the requirements of local gas codes and or ANSI Z223 1 CAN CGA B149 The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures above 2 PSIG 3 5 kPa Additionally the appliance must be isolated from the gas supply piping system by closing the appliance manual valve during any pressure testing as described above STEP 6 Install air filter Failure to do so could void the warranty STEP7 Attach the wrap around room cabinet by sliding it down over mounting brackets located on the top and lower right and left sides of the cooling chassis STEP 8 Plug the integral supply cord if provided into an appropriate receptacle or directly wire the appliance to the appropriate electrical supply Verify proper wiring of receptacle prior to attaching supply cord Incorrect wiring may impede operation of unit If this appliance is provided with a flexible service cord the three prong grounding plug is for your protection against shock hazard and should be plugged directly into a properly grounded three prong receptacle Do not cut or remove the grounding prong from the plug When this appliance is installed it must be electrically grounded in accordance with local codes or in the absence of local codes with the N
16. RRANTY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE USE OF EXTENSION CORDS IS NOT RECOMMENDED AND WILL VOID WARRANTY A QUALIFIED INSTALLER OR SERVICE AGENCY MUST PERFORM INSTALLATION OR SERVICE ALL LOCAL AND NATIONAL CODES MUST BE ADHERED TO WHEN INSTALLING THIS PRODUCT 2 E UNTSPECIRCATICNS This appliance is intended for new construction or retrofit replacement of most 42 x 16 Package Terminal Air Conditioners Confirm that the electrical rating of this appliance matches the electrical supply available before beginning installation refer to table on page 5 The efficiency rating of this appliance is a product of thermal efficiency rating determined under continuous operating conditions and is determined independently of any installed system Due to high temperatures the appliance should be located out of traffic and away from furniture and drapes Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or clothing ignition Young children should be carefully supervised when they are in the same room as the appliance Clothing or other flammable material should not be placed on or near the appliance Any safety screen or guard removed for service must be replaced before operating the appliance More frequent cleaning may be required due to excessive lint from carpeting bedding material etc It is imperative that control compartments burners and circulating air pass
17. above so that when chassis is pushed back into the sleeve the plenum follows the track provided below duct bottom Mount the front panel assembly without enclosure channel item 6 part 4080698 Install the extension item 10 part 4080707 or the connectors as needed Air delivery baffle item 4 part 2500188 located under the discharge air grill is factory positioned to provide a 50 50 distribution of air into each zone By removing it and cutting along the scored line results in 60 40 air distribution Removing the baffle completely will result in 70 30 split Duct extensions are also available without the grill in the following sizes 60 part 4080780 43 125 part 4080709 and 10 5 part 4080991 NOTE YOUR DUCT KIT ASSEMBLY MAY NOT CONTAIN ALL PARTS SHOWN HERE DEPENDING ON WHAT ACCESSORIES YOU ORDERED 54 1 250 MIN j FRONT PANEL ASSY 1 2 1600152 MAIN SUPPORT GS 2 2 1600210 BKT DUCT 652 SECONDARY 3 1 1900127 GS2 PLENUM 4 1 2500188 DUCT BAFFLE GS 5 1 4080698 ENCL CHANNEL GS2 6 1 4080699 ENCL ASSY GS2 DUCTED 7 1 4080701 DUCT MAIN GS2 8 1 4080702 DUCT BOTTOM GS2 9 1 4080703 END CAP DUCT GS2 10 1 4080707 DUCT EXT W GRILL GS2 11 1 4080709 ASSY DUCT EXT W O GRILL GS2 43 125 12 1 4080780 ASSY DUCT EXT W O GRILL GS2 60 000 13 1 4080991 ASSY DUCT EXT
18. ageways of the appliance be kept clean Use of extension cords is not recommended and will void the warranty Installation and repair should be done by a qualified service person The appliance should be inspected before use and at least annually by a qualified service person 1 Safety Information A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas If your unit uses LP propane be sure to smell next to the floor because LP propane gas is heavier than air and will settle on the floor C Use only your hand to turn the gas valve knob Never use tools If the knob will not turn by hand don t try to repair it Call a qualified service technician Force or attempted repair may result in fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and replace any part of the control system and any gas valve which has been under water Jc MODELS 207 209 212 215 Volts 115 230 208 277 115 230 208 277 115 230 208 277 230 208 277 7 500 7 500 7 300 7 500 9 500 9 500 9 300 9 500 12200 12 200 12 000 12 200 15 000 14 800 15 500 5 7 2 9 3 1 2 3 7 4 37 40 34 10 1 5 1 5 5 4 2 6 8 7 5 5 8 Watts Cool 660 658 640 647
19. air inlet located within 10 feet This provision does not apply to the combustion air intake of a direct vent appliance See Figure 1 Sidewall Venting Requirements 1 2 3 The vent terminal shall be at least 1 foot above grade The vent system of a direct vent appliance with an input of 50 000 BTU H or less shall be located at least 9 inches from any openings through which flue gases can enter Vent terminals shall not terminate over a public walkway or over an area where condensate or vapor cloud could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment EXCEPTIONS FOR INSTALLATION IN CANADA The vent terminal shall be located at least 1 foot from any window or door which can be opened in any building any non mechanical air supply inlet to any building or the combustion air inlet to any other appliance The vent terminal shall be located at least 6 feet from any mechanical air supply to a building The vent terminal shall not terminate above a meter regulator assembly within 3 feet horizontally of the vertical centerline of the regulator and shall be at least 3 feet from any gas service regulator vent outlet or electrical device The vent terminal shall not terminate less than 7 feet above a paved sidewalk or a paved driveway located on public property The vent terminal shall not terminate directly above a paved sidewalk or a paved driveway which is located between two s
20. an mode by pressing FAN key Select constant operation LOW or HIGH speed 3 Selecting AUTO will turn fan off NOTE When unit is shut off current settings are saved in memory When unit is turned back on these settings are restored 21 Temperature Display VU COLD LOW HIGH e p Island she HEAT COOL The pertoct mt Figure 9 Base electronic control keypad 2 00 For all units equi ed with electronic controls Low Temperature Protection LO indicates that s H ER the Low Temperature Protection feature is activated WARM C COLD LOW HIGH er AUTO SPEED SPEED HEAT COOL L I 1 FAN o The mi A standard feature of the Islandaire electronic control system is the Low Temperature Protection option If an indoor temperature of 55 degrees Fahrenheit or lower is detected the heat cycle will automatically activate even if the unit is in the OFF position While the Low Temperature Protection feature is activated the letters LO will be displayed The heat cycle will continue until the room temperature reaches 50 degrees Fahrenheit at which time the unit will satisfy and shut down All control functions will be locked out while LO is displayed Note Disconnecting the power supply to the unit is the only way to interrupt unit function wh
21. ated to the left of the controls See Figure 8 19 View Port Figure 8 View Port Detail If at any time the main valve fails to close completely and maintain a flame the full time flame sense circuit will detect and energize the combustion blower Should the main valve later close completely removing the flame signal the combustion blower will power off following the optional post purge period for reconditioning the system 20 Should overheating occur or the gas supply fail to shut off shut off the manual gas valve to the appliance before shutting off the electrical supply Base Electronic Control Operation See Figure 9 Turning Unit ON for Heating and Cooling 1 Press ON OFF key room temperature will appear in display 2 Oninitial startup press F C key to select temperature scale Celsius or Fahrenheit 3 Select mode by pressing HEAT or COOL key 4 Adjust set point by pressing WARM up arrow or COLD down arrow key while adjusting temperature set point will appear in display 5 Select fan mode by pressing FAN key Select constant fan operation LOW or HIGH speed or AUTO In AUTO the fan will cycle and select fan speeds based on heating or cooling demand Turning Unit OFF 1 Press ON OFF key temperature display disappears 2 Toturn fan off press FAN key until fan AUTO LED indicator is lit Fan Only Operation 1 Turn off unit by pressing ON OFF key temperature display disappears 2 Select f
22. ational Electrical Code ANSI NFPA 70 and or the CSA C22 1 Electrical Code 52145 CPERATINGINSTRUCTI CN LIGHTING OPERATING AND SHUT DOWN INSTRUCTIONS This appliance requires combustion air for heating operation Air is drawn from the outdoors through the rear grill assembly Do not block or obstruct air openings in the rear grill This appliance will automatically light itself in response to a thermostat call for heat To initiate heating operation turn on the manual valve in the gas supply piping and the manual valve located in the front right compartment of the appliance This procedure should be used on initial start up of thru wall air conditioning units On new installations and on units that may have been idle for a period of time procedure should take approximately ten minutes per unit to test adequately 15 Island r lt The perfect OFF HicooL 100001 OW HIGH AUTO PEED SPEED HEAT COOL Warmer TEMP Cooter Loos SETTING 1 FAN open Islandaire HEAT ICOOL The perfect fit ISLANDAIRE 4020047 Digital control plate Mechanical control plate 9 Figure 7 4 16 Press the FAN button on the selector switch and allow motor to reach maximum in the warm months If unit is in a warm area this should be approximately 15 to 30 seconds In cold months or cold areas this could take up to 90 s
23. bracket to nearest score marks on sides of sub base 3 Bend sides at score marks inward 90 degrees with pliers 4 Attach sub base to bottom flange of wall sleeve with 4 screws provided 50 Determine Distance Figure 23 Duct Kit Installed 52 Top Vien 5 437 1 2 1600152 MAIN SUPPORT GS 2 2 1600210 DUCT 552 SECONDARY 3 1 1900127 GS2 PLENUM 4 1 2200043 CHANNEL TOP GS2 5 1 2500188 DUCT BAFFLE GS 6 1 4080698 ENCL CHANNEL GS2 7 1 4080699 ENCL ASSY GS2 DUCTED 8 1 4080701 DUCT MAIN GS2 9 1 4080702 DUCT BOTTOM GS2 10 1 4080703 END CAP DUCT GS2 11 1 4080707 DUCT EXT W GRILL GS2 12 1 4080709 ASSY DUCT EXT W OUT GRILL GS2 43 125 13 1 4080780 ASSY DUCT EXT W O GRILL 60 000 14 1 4080991 ASSY DUCT EXT W O GRILL 10 500 15 4 6060019 SCREW 8 X SELF 1 4 IN HEX HEAD 16 6 6060020 SCREW 8 X PHIL PAN 17 6 6060026 SCREW 8 X PHIL PAN BLACK 18 2 6060034 LOCK NUTS 19 2 6060040 SCREW 8 X 5 AB POINT SLOTTED HEX 20 2 6060092 SCREW 10 32 X LONG PAN HEAD 21 1 6070046 GRILL JA CK HYD ROOM CABINET 22 1 WSGS2 WALL SLEEVE GS2 RECESSED METAL SLEEVE MAX 39 500 31 500 MIN 1 LONG FRONT PANEL ASSY E 53 Figure 24
24. combustible materials gasoline and other flammable liquids and vapors 25 periodic visual inspection of the through sight glass is needed The should characterized by a blue flame with well defined burner ports The burner is factory set for maximum performance however it can be removed from the unit to make air adjustments if necessary See Figure 10 for disassembly If the flame cannot be adjusted to achieve the desired burner flame the surface of the burner and each burner port should be cleaned Figure 10 Combustion Box Assembly See Page 62 for Item Details 26 LOOSEN SCREW SURFACE ROTATE AIR SHUTTER IGNITOR TO ADJUST AIR FLOW Figure 11 Burner Adjustment 27 The recommended method of cleaning flue gas passageways of the appliance is with a suitable flexible shaft soft bristle brush and or compressed air Disconnect electrical power before servicing Remove the combustion tube during any cleaning procedure Remove igniter The burner can then be cleaned with a soft brush without being removed from the combustion tube Ensure that the burner is centrally positioned around the gas orifice Should the appliance fail to operate the ignition control displays a small LED light with up to three flashing pulses as follows This LED light can be observed through the clear view port near user controls See Figure 8 Error Mode LED Indication
25. ct of jumper wires 1 Attach one start capacitor jumper wire clip to the compressor run capacitor yellow lead from the compressor This is the start winding of the compressor 2 Attach the other jumper wire clip to or hold in contact with the white lead or run lead of the compressor run capacitor This puts the start capacitor in series with the start winding of the compressor 3 Energize the compressor electrically with the thermostat or switch Immediately remove jumper wires after the compressor has started 4 Discharge the capacitor to eliminate possible shock from the holding charge There should be no need to repeat this procedure if the compressor is run for a short period of time to allow the system to function and to loosen up the tight compressor parts This is not a recurrent problem NOTE If the compressor fails to start after using these instructions refer again to the compressor section for removal and replacement of compressor 43 Figure 16 4 41 8 81 411 81 41 1 141 Figure 17 Figure 18 ISL NDARRE Figure 19 TIN EMT T RO 47 N 6 5 iL 48 Figure 21 80 11 m ACCESSCRIES Installation Instructions for GS Sub Base See Figure 22 1 Determine distance from finished wall to front of wall sleeve bottom flange 2 Measure determined distance from vertical
26. e appliance and to replace any part of the control system and any gas control that has been under water Ensure that there is adequate clearance for servicing and proper operation A minimum of 36 inches to the front of the wall sleeve is required to remove the appliance from the wall sleeve The installer is to ensure that adequate combustion and ventilation air is provided INSTALLATION PROCEDURE STEP 1 For installation of retrofit replacement package terminal air conditioners This unit will fit most existing 42 x 16 type wall sleeves by removing the existing front cabinet and air conditioner If using the existing wall sleeve and outdoor louver they must be inspected to ensure satisfactory condition prior to unit installation and louver design must be approved by the Islandaire Engineering Department For installation of new construction a wall sleeve must be installed through a 42 inch wide x 16 72 inch high hole in the exterior building wall See Figures 2 3 and 4 for wall sleeve framing dimensions Secure the wall sleeve to the surrounding studs by drilling two 1 8 inch diameter holes through both sides approximately in the center of studs using 34 pan head type screws supplied Shim if necessary to prevent the sleeve from bowing Make sure the wall sleeve is level from side to side and sloped 14 inch from front to rear DO NOT DRILL HOLES IN THE BOTTOM OF THE SLEEVE WATER DAMAGE WILL OCCUR Seal around the outside portion of the wa
27. e control repeats the prepurge cycle before another ignition attempt The control will attempt two additional ignition trials before going into lockout The valve relay will be de energized immediately and the combustion blower will be turned off following the optional post purge period Recovery from lockout requires a manual reset by either cycling the thermostat or switching the appliance OFF and ON If the thermostat is still calling for heat after one hour the control will automatically reset and attempt to ignite the burner again If the established flame signal is lost while the burner is operating the control will respond within 0 8 seconds The gas valve is de energized immediately and a new ignition sequence begins in an attempt to relight the burner If the burner does not light the control will de energized the gas valve The system will make two more attempts to relight the burner If the burner does not relight the control will go into lockout as noted previously If the flame is re established normal operation resumes Following burner ignition the circulating fan will delay starting until the heat exchanger warms up Following burner extinction the circulating fan will continue to operate until the heat exchanger cools down Circulating fan operation may terminate immediately if the appliance is switched OFF 18 The appliance will attempt up to three ignition trials with a purge period in between Should ignition not be
28. econds or more This allows time to warm up on HI speed Electronic Units Push fan button to cycle through Hi Low and Automatic Cycles Cooling Mode Press HI COOL button rotate thermostat counterclockwise until it stops The indoor fan motor will run WARNING IF OUTSIDE TEMP IS BELOW 55 DEGREES DO NOT START THE COMPRESSOR AT THIS TIME WAIT UNTIL WARMER WEATHER TO OPERATE COOLING the outside temperature is above 55 degrees rotate the knob clockwise The compressor and condenser fan motor will start Cool air should be felt at the discharge openings in a short period of time approximately 60 to 90 seconds Firmly press LO COOL button The indoor motor should reduce speed without affecting compressor or condenser motor speed Heat Mode Push the HEAT button on the selection console and establish the desired temperature setting on the thermostat or digital read out depending on the control system supplied SAT When heat is received thermostat the control will check the pressure differential switch for normally open contacts The combustion blower is then energized once the pressure switch contacts close a time delay begins and the hot surface igniter is activated Following the igniter heat up period the gas valve is energized for the trial for ignition period Should the burner fail to light or flame is not detected during the first trial for ignition period the gas valve is de energized and th
29. ermostat bulb from the clamp on the housing 6 Press down on front of pan and pull forward Pan should slip off the locating brackets and be ready to continue servicing on a bench 7 Remove three screws and orifice ring from sides of both blower housings 8 Loosen setscrews with allen torx wrench and slip off the shaft 9 Remove three screws in blower outlet to pan flanges Housing will be free to remove 10 Remove two motor mounting spring clamps on the end bell isolators of the motor They unsnap from the mounting cradle Remove screw holding ground wire Motor is now free to remove 11 Check drain hose for possible obstruction and clean pan of dirt or other items 12 Remount new motor and reassemble by reversing the above procedures NOTE Make sure vanes are in right direction for airflow Make sure that the wheels are centered in the housing and have proper clearances when running 13 Remount pan assembly into unit by inserting pan under evaporator coil making sure the rear of the pan is resting on the locating brackets Lift up the front and hold while attaching clamps to end plates of the coil Make sure pan is secure after clamps are tightened in place 14 Remount thermostat bulb in clamp on housing Reconnect motor to unit Remount the front panel on the chassis 15 Reconnect power source check and test unit CONDENSER MOTOR REPLACEMENT As this is a major service every effort should be made to inspect the condenser motor
30. heck the capacitor 1 Make sure all power to the unit has been turned off before opening or removing service panel This service should only be performed by a qualified technician Before touching the capacitors using an insulated screwdriver short the terminals to each other and to the cabinet gnd This should be done on both capacitors to reduce hazard of electrical shock 2 Remove one lead wire from the capacitor 3 Using an ohmmeter touch probes to terminals A slight deflection should occur then drop back to 0 reading 4 Reverse probes and touch to terminals Again a slight deflection should occur then drop back to 0 reading 5 If available a capacitor checker should be used to get true capacitance 6 If capacitor shows signs of failure replace with correct part 3 SWITCH CHECK TEST 8 REPLACEMENT Occasionally it may become necessary to service the switching circuit of the thru wall air conditioning units The following procedure is to aid you if this should become necessary See Figure 13 First test the switch according to the following to find out if the switch is the faulty item in the circuit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 sure the unit has been disconnected from power source Unplug open disconnect switch disconnect circuit breaker box or fuse box as required Check for power at unit junction box to insure power is off before proceed
31. ile the Low Temperature Protection feature is activated If desired this feature may be disabled by your qualified service provider 23 SHUT DOWN For extended shut down turn off the manual valve in the gas supply piping and the manual valve located in the front right compartment of the appliance Push the OFF button on the selection console and unplug power cord or turn off circuit breaker powering unit Note On electronic units if power is not disconnected the unit may activate indoor low temperature mode which will allow the appliance to maintain 55 degrees in the room space whether or not it is in the OFF position 24 SERVICING See Figures 16 22 for the proper wiring arrangement CAUTION Label all wires prior to disconnection when servicing controls Verify proper operation after servicing Periodically inspect outside louver combustion air intake and exhaust to make sure they are free of any obstruction or restriction It is imperative that the products of combustion are properly vented to the outside atmosphere and that all combustion air supplied to the burner is drawn from the outside atmosphere Periodically check the control compartment burner and air circulating passageways of the unit It is imperative that these areas be kept clean NOTE More frequent cleaning may be required due to excessive lint from carpeting bedding material etc The appliance area must be kept clear and free from
32. ill be three rubber grommets and steel sleeves in the mounting leg holes in the motor if provided These must be removed from the old motor and installed on the new motor mounting legs Reassemble unit exactly in reverse of the disassembly instructions using EXTREME caution when handling the coil and copper tubing assembly When re attaching motor leads into control box make sure that the wiring is routed and connected in exactly the same fashion as the old motor leads If wire colors of the old motor are not the same colors as the new motor refer to the wiring diagram shipped with the motor 42 START CAPACITOR USE Each air conditioning unit is 10096 run tested during manufacture Occasionally though when a unit has been shipped with a complete charge the compressor may be locked up due to oil drainage and or refrigerant migration If this occurs the compressor should be checked electrically See Compressor Section If the compressor has been checked electrically as per instructions 1 2 and 3 of the compressor section and no fault is found use an amp probe or other amp meter to determine if the compressor is tripping out on the overload under locked rotor amperage as noted on specification plate If this checks out it is recommended that a start capacitor or hard start kit be used to free the compressor Use the following instructions Use a 50 mfd 370 volt Start Capacitor with terminal leads and alligator type clips for quick disconne
33. ing with check tests Disconnect all wire terminals from the switch Connect test probe of ohmmeter or other continuity checking meter or device to terminal L1 of the switch Check for continuity as follows Push OFF button There should be no reading of continuity from L1 to any terminal Push HI COOL button Cooling with hi speed evaporator motor There should then be continuity between L1 terminal and terminals 1 2 and 4 only Push LO COOL button cooling with low speed evaporator motor There should then be continuity between terminal L1 and terminals 1 3 and 5 only Push HEAT button There should be continuity between terminal L1 and terminals 5 amp 6 and L2 amp H Push FAN ONLY button There should be continuity between L1 terminal and terminal 4 only With buttons for HI COOL LO COOL or FAN pushed there should then be continuity between terminal L2 and terminal 7 No continuity when HEAT button is pushed Any deviation from above information would indicate that the switch is faulty and should be replaced according to the following instructions Remove thermostat knob control plate and chassis front panel Remove the two screws and the switch will drop down Remove thermostat from control box Remove wiring from old switch and attach to new switch one wire at a time to insure proper wiring Refer to wiring diagram Reassemble by reversing the above instructions 32 5 819 0 40 19 9684 sjo 3uo5
34. ingle family dwellings The vent terminal shall not terminate underneath a porch veranda or deck unless the veranda porch or deck is open on a minimum of two sides beneath the floor and the distance between the top of the vent terminal and the underside of the veranda porch or deck is at least 1 foot LUE NON MECHANICAL 1 1 AIR SUPPLY OR Termination of COMBUSTION AIR SUPPLY outlined sea c OUTSIDE not permitted LOUVER 1 TERMINAL VENT TERMINAL WINDOW MINIMUM 6 FEET TERMINAL 127 mm 1 8m ABOVE GRADE MINIMUM y 9 INCHES 22 7 229 mm RY MINIMUM THIS WILL PROVIDE 12 MINIMUM 300 mm ABOVE GRADE TO VENT i TERMINAL LOCATION A vent is permitted under a veranda porch or deck only where there are 2 fully open sides beneath the floor minimum of 12 inches S00mm must be maintained from the vent to the underside of the veranda porch or deck In areas with low street gas pressures a service regulator vent may not be installed Maintain required clearances Louver not shown regardless since street service may be updated in the future This vent must be fitted with a cap in accordance with the vent manufacturer s installation instructions Figure 1 Sidewall Venting Requirements 8 Do not use this appliance if any has been under water Immediately a qualified service technician to inspect th
35. inst brackets With the other hand slide screws through slot 3 Secure four screws and four nuts to mount louver _ WALL J SLEEVE Figure 27 Note Louver is designed to be installed the inside 58 REPLACEMENT PARTS EXPLODED VIEW Figure 28 Chassis Parts 59 1 1100227 FIREWALL GS2 2 1200110 SHROUD GS2 3 1500062 DRAIN PAN METAL LONG ALU GS2 4 1600152 MAIN SUPPORT BRACKET GS 5 1600236 MOUNT GS2 G3 COMB BLOWER UNIVERSAL 6 1800350 COND COVER GS2 7 1800351 PANEL FRONT GS2 8 1900125 SAFE OFF PLT GS2 9 2100265 SUPPORT RIGHT 682 10 2100266 SUPPORT LEFT GS2 11 2200043 CHANNEL 652 12 2300070 ANGLE GS2 13 2300071 ANGLE SIDE LT GS2 14 2300072 ANGLE SIDE RT GS2 15 2500159 LIMIT COVER GS EG 16 2500273 BKT ENCL GS2 RT 17 2500276 GS2 FLUE ASSY 18 4010XXX VENT ASSEMBLY 19 4010094 COMBUSTION BASE ASSEMBLY 20 4010XXX GAS VALVE ASSEMBLY 21 4080700 ENCL ASSY GS2 STD 22 4080704 DUCT MAIN ASSY GS2 23 4080707 DUCT EXT W GRILL GS2 24 4080709 ASSY DUCT EXT W OUT GRILL GS2 25 4080710 SUBBASE NON STRUCT GS2 26 6020XXX CONDENSOR MOTOR 27 6020XXX COMBUSTION AIR BLOWER ASSEMBLY 28 6020XXX COMPRESSOR 29 6030 EVAPORATOR COIL 30 6030XX CONDENSOR COI
36. lamps to end plates of the coil Make sure pan is secure after clamps are tightened in place Connect drain hose to drain pan Remount thermostat bulb on housing Reconnect motor wiring harness to quick connector Remount front panel on chassis Reconnect power source check and test unit 38 Figure 15 Fan Deck Assembly See Page 64 for Item Details BLOWER HOUSING REPLACEMENT See Figure 15 dz 2 3 4 5 6 Make sure that the unit has been disconnected from the power source Unplug or disconnect at circuit breaker box or fuse box as required Make sure that power is off at the unit Remove front decorative cabinet panel and remove front panel of chassis by removing all panel screws on chassis NOTE COMPLETE FAN DECK ASSEMBLY MUST BE REMOVED TO SERVICE THESE PARTS Remove two clamps one on each end of pan attached to coil end plates with screws Disconnect the drain hose at the drain pan Unplug motor wires from the quick connector Remove thermostat bulb from the blower housing 39 7 8 9 10 11 12 13 14 Press down on front of pan and pull forward Pan should slip off the locating brackets and be ready to continue servicing on a bench Remove three screws and orifice ring from side of blower housing Loosen wheel setscrew with allen torx wrench and slip off shaft Remove three additional screws in blower outlet to the pan flanges Housing will be free to remove Replace with new hou
37. ll sleeve using weatherproof caulking to form a seal against rain snow and air leakage 29 2 HEADER STEEL LINTEL IN BRICK CONSTRUCTION n n 42102 1650 FINISHED FLOOR SUB LOOR NOTE Units approved for O clearance to combustible constructions top sides and botom Front and rear clearance not applicable as there can be no construction Figure 2 Wall Sleeve Framing Dimensions STEP 2 Important Before installing louvers above the first floor be sure to secure louver with a safety line to ensure louver does not fall Attach the outdoor louver from the inside by maneuvering the louver through upright supports in the sleeve Use the four 8 32 nuts and bolts to fasten the louver to the left and right sides of the wall sleeve Slide the Islandaire Series GS air conditioner into the wall sleeve Verify proper sealing between the air conditioner and wall sleeve also between the air conditioner and the outdoor louver Lock the unit into the wall sleeve using the 8 sheet metal screws supplied Consult Islandaire for information for accessory kits which may be required for some retrofit installations 10 X 1114 MIN 11 15 SUB BASE REQUIRED WHEN OVER 1 14 SURFACE OF FINISHED INTERIOR WALL CABINET FRONT rg SURFACE OF FINISHED EXTERIOR WALL CAULK ALL AROUND WALL SLEEVE ees GRILL MOUNTING HOLES AND SCREV S BY INSTALLER
38. n check thermostat wiring 7 blinks Inadequate ground 8 blinks Outdoor coil low temperature switch open only if Heat Pump configured by DIP switch disables compressor operation 34 j 9 blinks Fan limit switch open only if Hydronic heat gas heat configured by DIP switch Disables fan in gas heat mode and Hydronic heat mode k 10blinks Configuration read failure check setting on configuration switch l 11 blinks Module mismatch error occurs if board versions are mismatched 2 Automatic System Component Test to be performed by a qualified service technician 1 Un plug or disconnect power to the unit 2 Gain access to the main board mounted within the electrical box Locate the 9 pin connector labeled EXPANSION on the main board Pin 1 is located closest to the smaller connector labeled IAT See Figure 14 PIN 9 JUMPER 1 8 PIN 817 S 23 EH Figure 14 ie 18 T 4 5 6 7 8 Place a jumper between 6 and 9 of the EXPANSION connector Be sure any wires or parts moved during installation of jumper will not cause an electrical short Reapply power to the unit and wait approximately 20 seconds and the unit will enter an automatic system component test sequence The system automatically runs through the operational functions of each component within the unit If the unit is equipped with a displa
39. ontrol knob shaft Loosen the two screws and thermostat will drop down for easy removal Attach wiring to replacement thermostat at time of removal from failed thermostat to insure proper hookup without reversing the circuit Check wiring diagram Reinstall the new thermostat using the reverse procedure of removal instructions Remove old thermostat capillary tube and bulb from hole in panel and clamp on blower housing Install new bulb through hole in panel and into clamp on blower housing Test unit 10 Check for proper operation of the unit 11 Reassemble thermostat knob electric box top and decorative panel 29 COMPRESSOR 8 9 Make sure the compressor is at fault before starting a replacement procedure This should be done by a qualified technician A compressor that fails to start may appear to be faulty when in reality the fault may be elsewhere Check all other possibilities first Examine the switch thermostat capacitors wiring and incoming power for electrical and or mechanical misapplication or malfunction Disconnect unit from power source by unplugging disconnecting switch or disconnect at circuit breaker or fuse box before further test Check compressor motor to see if it is electrically grounded or open If no fault is found check motor resistance to determine if it shorted in motor winding If compressor is grounded or shorted out this is a possible burnout situation and care should be taken when furthe
40. pliance main gas valve must be disconnected from the gas supply piping system during pressure testing of that system at test pressures in excess of 1 2 psi The appliance must be isolated from the gas piping system by closing equipment shutoff valves during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psi The gas fired heating design of this appliance requires that the installation of this appliance must conform with local codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or National Gas and Propane Installation Code CSA B149 1 This appliance is only for use with the type of fuel indicated on the rating plate This appliance is not convertible for use with other gases Inlet gas pressure Natural Gas minimum 5 5 W C maximum 13 5 W C Liquefied minimum 11 W C maximum 13 W C Minimum inlet pressures must be maintained for purpose of adjustment 26 Confirm that Code stipulated vent terminal positioning restrictions for minimum clearance distances to grade level below the rear of the wall sleeve gas and electric meters regulators and relief equipment or adjacent public walkways adjacent buildings openable windows and other building openings are consistent with local codes and or ANSI Z223 1 and or CSA B149 1 The ANSI 7223 1 specifications include the following The vent terminal shall terminate at least 3 feet above any forced
41. r work is done to insure safety to eyes and skin from acid in the refrigerant caused by burnout When breaking the refrigerant line to discharge gas or liquid use extreme care The unit should be moved to an area suitable for the procedure if possible NOTE IT IS THE RESPONSIBILITY OF THE SERVICE PERSON TO PROPERLY RECOVER AND RECYCLE ALL REFRIGERANT IN THE SEALED SYSTEMS ACCORDING TO EPA GUIDELINES Remove compressor and install proper replacement Consult Customer Service Department if in doubt See Figure 12 If compressor was a burnout install proper approved filter drier in the refrigeration circuit It may be necessary to fabricate new copper tubing Make sure of proper material and line size If excessive burn has occurred use a suction line filter drier also Tubing changes may be necessary 10 If excessive acid was found in the system unit should be blown out with dry nitrogen before final hookup of new compressor or a second burnout may occur very shortly Any oil lost during this procedure must be replaced 11 After braze has been completed leak check the unit and evacuate the system Then recharge with Refrigerant 22 to the amount specified on the nameplate 30 Figure 12 Compressor CAPACITORS On occasion problems of compressor condenser or evaporator motor not starting cycling or running in reverse may be attributed to capacitor failure or failure of the compressor valves If you have such a problem first c
42. sing and re assemble all parts by reversing the above procedure making sure that the blower wheel rotation is correct and the blower wheel is centered in the housing when running Remount pan assembly into unit by inserting pan under evaporator coil making sure the rear of the pan is resting on the locating brackets Lift up the front and hold while attaching clamps to end plates of the coil Make sure pan is secure after clamps are tightened in place Connect drain hose to drain pan Remount thermostat bulb on the housing Replug the motor into unit Remount front panel on chassis Reconnect power source check and test unit EVAPORATOR MOTOR REPLACEMENT See Figure 15 It may be necessary to replace the evaporator motor but first make sure that it is the motor that is at fault Make sure that the unit has been disconnected from the power source Unplug or disconnect from power at circuit breaker box or fuse box as required Make sure that power is off at the unit Remove front panel of chassis by removing all panel mounting screws NOTE Unplug motor and check for short or open motor windings with a meter or circuit tester If no fault is found in the motor check back on the circuit to establish faulty part If replacement is required the complete fan deck assembly must be removed for this service Remove two clamps one on each end attached to coil end plates with screws Disconnect the drain hose at the drain pan 40 5 Remove th
43. thoroughly prior to removal to be absolutely sure the motor is faulty 1 Make sure that the unit has been disconnected from the power source Unplug or disconnect at circuit breaker box or fuse box as required Make sure power is off at the unit 41 7 8 9 10 11 Check motor lead wires black 8 white for short or open in motor winding with meter or other circuit tester Repeat test for red to white blue to white black to white purple to white and test the motor run capacitor If no fault is found with motor or capacitor check unit to establish faulty part To replace the condenser motor use the following steps Remove chassis from wall sleeve Remove condenser cover screws from left and right sides of the condenser coil and top of shroud Lift off condenser cover Disconnect four motor wires Pull wires through firewall hole on motor side and remove motor lead clamp on firewall Record location of wires in control box for future reference Remove two screws to firewall at top of condenser fan shroud and remove two screws attaching coil to bottom pan flange Loosen setscrew on fan blade and move fan blade forward towards coil Carefully lift coil and shroud above pan flange and pull out from the unit on the left side being careful not to rupture the copper tubing This service should be performed by a qualified technician only Remove fan blade three nuts and ground wire Motor may now be removed from the unit There w
44. y an abbreviated description of each function will be displayed display is where temperature and set points are viewed as each function is tested Table 1 describes the abbreviated descriptions that are displayed and unit operation Only functions available to the unit will be tested Others will simply be ignored This allows the technician to perform a quick field diagnostic of whether the compressor motor speed or heating components function properly during the automatic test function Service efforts can be directed to the various controls that operate the system Un plug or disconnect power to the unit Remove the jumper that was installed on pins 6 and 9 of the expansion connector Reapply power to unit to resume normal operation 36 Table 1 Time Phase Display LEDs Unit Operation seconds Notes 1 F1 Low Fan LO FAN 5 2 OFF 1 3 F2 Med Low Fan MED LO FAN 5 Will skip if base 4 5 OFF 1 Will skip if base 5 F3 Med High Fan MED HI FAN 5 Will skip if base 6 1 Will skip if 7 F4 High Fan HI FAN 5 8 OFF 1 9 HP Low Fan F C Auto RV COMP LO FAN 10 Skip if no Heat Pump 10 C Low Fan F C Auto COMP LO FAN 10 Skip if Heat Pump 11 1 12 Low Fan C Auto ELEC HEATER LO FAN 10 Skip if no Elec Heat 13 5 2 1 Skip no Heat 14 HD Low Fan F C Auto HYDRONIC LO FAN 5 Skip if no Hydronic 15 5
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