SERVICE INSTRUCTION - HVAC-Talk
Contents
1. ELECTRIC BD AIR COIL EEPGHRIQH ALME ABVEASING VALVE ma nuw VALVES OFEREPGAR Qa INDOOR BLOWER AIR FILTER FILTER GRILLE ARNILLANY HEAT c nbb NSSATE DAA INSIDER DOWNFLOW MODELS REFRIGERANT SYSTEM OPERATION A good understanding of the basic operation of the refrigeration system is essential for the service technician Without this understanding accurate troubleshooting of refrigeration system problems will be more difficult and time consuming if not in some cases entirely impossible The refrigeration system uses four basic principles laws in its operation they are as follows 1 Heat always flows from a warmer body to a cooler body 2 Heat must be added to or removed from a substance before a change in state can occur 3 Flow is always from a higher pressure area to a lower pressure area 4 The temperature at which a liquid or gas changes state is dependent upon the pressure The refrigeration cycle begins at the compressor Starting the compressor creates a low pressure in the suction line which draws refrigerant gas vapor into the compressor The compressor then compresses this refrigerant raising its pressure and its heat intensity temperature The refrigerant leaves the compressor through the discharge line as a HOT high pressure gas2. FROM COMPRESSOR DISCHARGE 4 WAY REVERSING VALVE Electrical Circuit and Coil Reversing valve coil is energized in the heating cycle only 1 5 for heating valve should shift 2 Check for line voltage at the defrost relay terminal 2 and the common terminal post purge relay Ifline voltage is not present check the power supply Testing Coil 1 Turn off high voltage electrical power to unit 2 Unplug the electrical leads from the reversing valve coil 3 Check for electrical continuity through the coil If you do not have continuity replace the coil 4 Checkfrom each lead of coil to the copper liquid line as itleaves the unit or the ground lug There should be no continuity between either of the coil leads and ground if there is coil is grounded and must be replaced 5 coil tests okay reconnect the electrical leads 6 Make sure coil has been assembled correctly Checking Reversing Valve NOTE You must have normal operating pressures before the reversing valve can shift Check for proper refrigerant charge Sluggish or sticky reversing valves can sometimes be remedied by reversing the valve several time with the airflow restricted to increase system pressure To raise head pressure during the cooling season the airflow through the outdoor coil can be restricted During heating the indoor air can be restricted by blocking the return air Dented or damaged valve body or capillary tubes can pre
3. CHECK OUTLET VOLTAGE ON TIME DELAY AFTER WAITING 5 TRANSFORMER IS BURNED OUT REPLACE IS THE COMPRESSOR CONTACTOR PULLED IN CHECK FOR 240 VOLT PRIMARY THEN CHECK COMPRESSOR CAPACITOR COMPRESSOR OUTDOOR FAN CONTACTOR MOTOR LEADS IS OUTDOOR FAN DEFECTIVE MOTOR REPLACE IF NO VOLTAGE INDICATED CHECK Y CIRCUIT TIME DELAY IS DEFECTIVE REPLACE IF 24 VOLTS BETWEEN X amp RON IS AT FAULT IS RELAY ENERGIZED FAULT LIES IN INDOOR FAN MOTOR OR WIRING CONNECTION FAN RELAY IS DEFECTIVE meys Duinoouso qno4 Low Suction Pressure Low Load Conditions Low Air Flow Across Indoor Coil Refrigerant System Restriction Undercharged Moisture in System REFRIGERANT SYSTEM DIAGNOSIS COOLING High Suction Pressure High Load Conditions High Air Flow Across Indoor Coil Reversing Valve not Fully Seated Overcharged Defective Compressor Low Head Pressure Low Load Conditions Refrigerant System Restriction Reversing Valve not Fully Seated Undercharged Defective Compressor Troubleshooting Chart Cooling High Head Pressure High Load Conditions Low Air Flow Across Outdoor Coil Overcharged Non Condensable air in System 33 34 Troubleshooting Chart Heating Low Suction Pressure Low Air Flow Across Outdoor Coil Refrigerant System Restriction Undercharged Moisture in System REFRIGERANT SYSTEM DIAGNOSIS HEATING High
4. SERVICE INSTRUCTION DEFROST CONTROL FIXED TIME INTERVAL S116 JANUARY 06 2000 51 5116 CONSOLIDATED TECHNOLOGY CORPORATION P O BOX 1537 OLIVE HILL KY 41164 PHONE 606 286 5366 FAX 606 286 2700 Safety Heat pumps are appliances in which service if improperly performed may result in personal injury or damage to equipment or property Follow proper and workmanlike safety procedures Before proceeding carefully read and understand the entire instructions recognize each component and understand its function More than one design is covered by these instructions Refer to section 2 to determine the design you have Most down flow units will need to be removed for sensor access SECTION 1 PARTS LIST Before you begin changing this control first check the kit to make sure that you have the complete kit The items should be as follows description CTC Part No Qty Instruction Manual SI 8116 1 Defrost Control 24015401 1 Defrost Sensor 24016207 1 Nylon Tie Strap 22015602 2 Presstite x 6 22010106 1 Wire Black W1801000X2560 3 Relay Defrost Heater 24015000 1 Screws 20025007 2 SECTION 2 UNIT DESIGN Units prior to date code 96050076 containing a standard fan relay will not need the additional defrost heater relay Refer to wiring diagram on page 5 b Units falling between date codes 96050076 and 98020066 containing a post purge delay off fan relay will need the defrost
5. 320 68 00 68 00 320 320 330 330 68 00 68 00 340 340 Fresh Air CF 65 65 65 Indoor Motor Indoor Motor Amps 1 0 1 0 1 0 Outdoor Motor 1 3 1 3 1 3 Outdoor Motor Amps MODELS COOLING DA 1 4 1 4 1 4 TA 43000 43000 48000 48000 Cooling Power W 4500 4500 5300 5300 58000 6450 20 VEEHBGK25 SEER 9 8 9 8 9 7 9 7 9 8 Cooling SHR ELECTRICAL 0 72 HEAT 10 0 0 72 DATA 15 0 0 69 15 0 0 69 20 0 0 72 20 0 Heater Size KW Heating Cap Btu h Heating Power W 34100 10000 51150 15000 51150 15000 68200 20000 68200 20000 Heating Current A HEAT PUMP Heating Cap Btu h 41 6 62 4 62 4 83 2 83 4 Heating Power W Heating Current A ELECTHRI Voltage 230 208 230 208 230 208 230 208 230 208 230 208 LRA Comp A 104 0 104 0 129 0 129 0 169 0 169 0 Min Ckt Amps A 33 52 33 26 52 40 5 26 52 40 5 52 52 49 52 52 49 26 52 52 Power Connecti Unit Width in Hard Wire Hard Wire Hard Wire Hard Wire Hard Wire Hard Wire Unit Depth in Unit Height in ipping Weight Ibs Indoor CF If THE USA It matters tiste uste R Fresh Air Indoor
6. vapor The refrigerant enters the condenser coil where it gives up some of its heat The condenser fan moving air across the coil s finned surface facilitates the transfer of heat from the refrigerant to the relatively cooler outdoor air When a sufficient quantity of heat has been removed from the refrigerant gas vapor the refrigerant will condense i e change to a liquid Once the refrigerant has been condensed changed to a liquid it is cooled even further by the air that continues to flow across the condenser coil The system design determines at exactly what point in the condenser the change of state i e gas to a liquid takes place In all cases however the refrigerant must be totally condensed changed to a liquid before leaving the condenser coil The refrigerant leaves the condenser coilthrough the liquid line as a WARM high pressure liquid It next will pass through the refrigerant drier if so equipped It is the function of the drier to trap any moisture present in the system contaminants and LARGE particulate matter The liquid refrigerant next enters the metering device The metering device is a TXV The purpose of the metering device is to meter i e control or measure the quantity of refrigerant entering the evaporator coil Since the evaporator coil is under a lower pressure due to the suction created by the compressor than the liquid line the liquid refrigerant leaves the metering device e
7. If the contactor is not being energized Pulled In it may be checked as follows A check across the two 2 coil terminals of the contactor should indicate 24 Volts during a call for COOLING and HEATING If 24 volts IS indicated and the contactor does not pull In the contactor is faulty either a bad coil or mechanically stuck Typical Double Pole Contactor If 24 volts is NOT indicated check any optional controls i e High Pressure or Low Pressure Switches which may be wired in series with the compressor contactor Next check across Y and C of the units Low voltage Control circuit during a call for COOLING or HEATING This should also indicate 24 volts If not there may be problems with the thermostat control wiring or the Low control voltage transformer Problems with the transformer can quickly be ruled out by jumpering between R amp G ofthe units low control voltage circuit or switching the FAN switch on the thermostat subbase from AUTO to ON Once the transformer has been determined to be good a jumper placed between R and Y of the INDOOR units low control voltage circuit should cause the contactor coil to be energized If so the problem is in the thermostat or thermostat wiring If not the problem is in the wiring between the Low Control voltage terminal block and the contactor From Contactor Common T1 High Pressure Switch Y T2 1 24V Out to Contactor O Anti cycl
8. Motor Indoor MotorAmps ERI 3 1 Outdoor Motor 1 3 2 1 3 2 Outdoor Motor Amps 5 0 5 0 23 Wiring Diagram Index Model Type All Standard Air Conditioners Air Conditioners with Water Coil All Standard Heat Pumps Frost Free Passive Defrost Heat Pumps Time Delay Relay 24 Wiring Diagram All Standard Air Conditioners With Electric Heat 208 230 V 1 Ph 60 Hz SUPPLY COMPRESSOR OPTIONAL CONTACTOR NOT Li __ T INCLUDED ON ALL UNITS COMPRESSOR 9 COMPRESSOR CONTACTOR 2 L2 Q c RELAY HEATER HEATER CONTACTORS AUX HEATER OPTIONS CONTACTORS L1 T1 x l a z LE FREEZEUP PRESSURE THERMOSTAT SWITCH FAN RELAY 25 Wiring Diagram Air Conditioner With Water Coil 208 230 V 1Ph 60 Hz SUPPLY COMPRESSOR CONTACTOR L1 T1 O TER cO OW WATER PUMP RELAY Relay In the A C control box Pump Is Inside the water coll module TRANS PRIMARY 208 V TAP 1 o 230 V 0000 A R B SECONDARY 24 VOLTS FREEZE UP THERMOSTAT TERMINAL BLOCK OPTIONAL NOT INCLUDED ON ALL UNITS 26 Wiring Diagram All Standard Heat Pumps 208 230 Ph 60 Hz Supply INCLUDED ON ALL OPTIONAL NOT UNITS 80W 4 L DRAIN LINE HEATER HEATER G O CONTACTORS TRANSFORMER PRIMARY 27 Wiring Diagram Fro
9. Suction Pressure Outdoor Ambient Too High for Operation in Heating Reversing Valve not Fully Seated Overcharged Defective Compressor Low Head Pressure Refrigerant System Restriction Reversing Valve not Fully Seated Undercharged Defective Compressor High Head Pressure Outdoor Ambient Too High For Operation In Heating Low Air Flow Across Indoor Coil Overcharged Non Condensables air in System Use Factory Certified Parts Friedrich FRIEDRICH AIR CONDITIONING CO Post Office Box 1540 e San Antonio Texas 78295 1540 4200 N Pan Am Expressway San Antonio Texas 78218 5212 210 357 4400 e FAX 210 357 4480 Visit us on the Intemet at www friedrich com INVBSVC 03 02 35
10. Voltage should be at or above minimum voltage of 197 VAC as specified on the rating plate If less than minimum check for cause of inadequate power supply i e incorrect wire size loose electrical connections etc The compressor time delay relay will have to be bypassed for this test Do not leave the time delay bypassed when the test is completed Amperage L R V Test The running amperage of the compressor is the most important of these readings A running amperage higher than that indicated in the performance data indicates that a problem exists mechanically or electrically Single Phase Running and L R A Test NOTE Consult the specification and performance section for running amperage The L R A can also be found on the rating plate 18 Select the proper amperage scale and clamp the meter probe around the wire to the C terminal of the compressor Turn on the unit and read the running amperage on the meter If the compressor does not start the reading will indicate the locked rotor amperage L R A Internal Overload The compressor is equipped with an internal overload which senses both motor amperage and winding temperature High motor temperature or amperage heats the overload causing it to open breaking the common circuit within the compressor Heat generated within the compressor shell usually due to recycling of the motor is slow to dissipate It may take anywhere from a few minutes to several hours fo
11. all the registers are open 5 Determine the external static pressure with the blower operating 6 Refer to the Air Flow Data for your system to find the actual airflow 7 If the actual airflow is either too high or too low check the ductwork and make appropriate changes EXAMPLE Airflow requirements are calculated as follows 1 1 2 TON SYSTEM 18 000 Btu Operating to full capacity 230 volts with dry coil measured external static pressure 20 Air Flow 500 CFM It is also important to remember that when dealing with INSIDER and VERT I PAK B Series units that the measured External Static Pressure increases as the resistance is added externally to the cabinet Example duct work dirty filters grilles Checking Approximate Airflow If an inclined manometer or Magnehelic gauge is not available to check the External Static Pressure or the blower performance data is unavailable for your unit approximate air flow call be calculated by measuring the temperature rise then using the following criteria Electric Heat Strips The approximate CFM actually being delivered can be calculated by using the following formula KILOWATTS X 3413 Temp Rise X 1 08 DO NOT simply use the Kilowatt Rating of the heater i e 5 0 10 0 15 0 etc as this will result in a less than correct airflow calculation Kilowatts may be calculated by multiplying the measured voltage to the unit heater times the measured current draw of all he
12. end of the wire to the W terminal of the thermostat subbase and the other to the R terminal 3 Turn the power on and wait approximately one minute then read meter 4 Divide the meter reading by 10 to obtain the correct anticipator setting If an ammeter is not available set the heat anticipator as shown below HEAT ANTICIPATOR INDICATOR EM HT HEAT OFF COOL 5 Kw and 10 Kw The Anticipation Setting for the 5 and 10 Kw is 0 3 TEMPERATURE SELECTOM THERMOMETER L k Em SEAT FAM SYSTEM SWITCH FAN SWITCH The Honeywell T841A was the primary thermostat provided and used with the INSIDER heat pump prior to January 1999 The T841A is a heat pump thermostat with one stage of cooling and two stages of heat This thermostat has two mercury bulbs making accurate leveling a requirement for proper operation HEAT ANTICIPATOR INDICATOR EM HT HEAT OFF COOL Anticipation Setting for the 15 KW is 0 6 In April 2000 the White Rogers 1F59 13 became the primary thermostat provided and used with the INSIDER and VERT I PAK B Series heat pump The 1F59 13 is an electronic heat pump thermostat providing control without mercury bulbs The electronic digital type thermostat should be leveled for aesthetics FLUP SAITCH COVER THERMOMETER FAN FAITH gyarEM TEMPERAT
13. interval time i e 30 60 or 90 minutes has been reached Since it is undesirable to wait this amount of time to check control operation an ACCELERATOR has been designed into these controls to significantly reduce the defrost interval time FOR TESTING PURPOSES ONLY Controls are equipped with a pair of terminals identified as TEST or TST which when will accelerate the selected defrost interval time The method of jumpering the test pins varies slightly however based on the particular control With the TEST TST pins jumpered and if the defrost sensor remains closed the unit will go into the Defrost mode of operation every 7 14 or 21 seconds depending upon interval selected and or type of control The unit will then remain in defrost until the accelerated TIMED forced termination period 2 3 seconds depending upon control is reached as long as the jumper remains in place and the defrost sensor remains closed or jumped out EXTENDED OPERATION IN THIS MODE IS NOT RECOMMENDED During defrostthe reversing valve solenoid willbe deenergized the outdoor fan motor will be de energized and indoor supplemental second stage heat will normally be energized The identification ofthe terminal on the control board used to accomplish these function varies however with the particular control By referring to the wiring diagram for your particular unit you should be able to determine where what te
14. small amount of oil from the suction stub of the defective compressor into a clean container 5 Usingan acid test kit one shot or conventional kit test the oil for acid content according to the instructions with the kit 6 If any evidence of a burnout is found no matter how slight the system will need to be cleaned up following proper procedures 7 Install the replacement compressor 8 Pressurize with a combination of R 22 and nitrogen and leak test all connections with an electronic or Halide leak detector Recover refrigerant and repair any leaks found Repeat Step 8 to insure no more leaks are present 9 Evacuate the system with a good vacuum pump capable of a final vacuum of 300 microns or less The system should be evacuated through both liquid line and suction line gauge ports While the unit is being evacuated seal all openings on the defective compressor Compressor manufacturers will void warranties on units received not properly sealed Do not distort the manufacturers tube connections 10 Recharge the system with the correct amount of refrigerant The proper refrigerant charge will be found on the unit rating plate The use of an accurate measuring device such as a charging cylinder electronic scales or similar device is necessary Expansion Valves INSIDER and VERT I PAK B Series Systems use a balance port thermostatic expansion valve for the metering device The expansion valve is designed to maintain a c
15. use two 2 circuit breakers Due to continuing research in new energy saving technology specifications are subject to change without notice 22 _B SERIES CHASSIS SPECIFICATIONS MODEL 5 COOLING Cooling Cap DATA Cooling Power W SEER Cooling SHR ELECTRICAL HEAT DATA 10 0 10 0 15 0 Heater Size KW Heating Cap Btu h 17050 5000 34100 10000 5 0 10 0 17050 34100 34100 10000 51150 15000 10 0 15 0 34100 51150 Heating Power W Heating Current A Heating Cap Btu h 20 8 41 6 5000 10000 20 8 41 6 22000 22000 41 6 62 4 10000 15000 41 6 62 4 34000 34000 Heating Power W 2000 2000 3300 3300 Heating Current A ELECTRICAL Voltage V DATA 230 208 230 208 230 208 15 0 15 0 9 3 3 2 3 2 230 208 230 208 230 208 230 208 230 208 LRA Comp A 42 5 42 5 56 0 56 0 12 5 72 5 88 0 88 0 Min Ckt Amps A 14 26 14 52 16 7 26 16 7 52 22 8 52 22 8 26 52 27 9 52 27 9 26 52 Power Connection PHYSICAL D Hard Wire ATA 30 00 Hard Wire 30 00 Hard Wire Hard Wire Hard Wire 30 00 Hard Wire 30 00 Hard Wire Hard Wire Unit Width in Unit Depth in 21 00 68 00 21 00 68 00 30 00 30 00 21 00 21 00 21 00 68 00 21 00 68 00 30 00 30 00 12 00 12 00 Shipping Weight Ibs AIRFLOW Indoor CF 320
16. GE TERMINAL DESIGNATION 1F59 THERMOSTAT Tm NOT USED Black Supply Circuit The system cannot be expected to operate correctly unless the system is properly connected wired to an adequately sized single branch circuit Check the installation manual and or technical data for your particular unit and or strip heaters to determine if the circuit is adequately sized Supply voltage To insure proper operation supply voltage to the system should be within five 5 percent plus or minus of listed rating plate voltage Supply voltage to the unit should be a nominal 208 230 volts It must be between 197 volts and 253 volts Supply voltage to the unit should be checked WITH THE UNIT IN OPERATION Voltage readings outside the specified range can be expected to cause operating problems Their cause MUST be investigated and corrected Control Low Voltage To insure proper system operation the transformer secondary output must be maintained at a nominal 24 volts The control low voltage transformer is equipped with multiple primary voltage taps Connecting the primary supply wire to the tap i e 208 and 240 volts that most closely matches the MEASURED supply voltage will insure proper transformer secondary output is maintained Electrical Ground Grounding of the electrical supply to ALL UNITS IS REQUIRED for safety reasons 2 C9 amp mo VOLTAGE TERMINAL BLOCK Terminals O L and E are not use
17. S DEFECTIVE REPLACE CHECK TERMINALS 1 amp 2 ON DEFROST RELAY FOR CLOSED CONTACT CONTINUITY OF WIRE TO B TERMINAL THERMOSTAT THERMOSTAT IS DEFECTIVE REPLACE WIRES BETWEEN CIRCUIT BREAKER amp TRANSFORMER ARE DEFECTIVE CHECK CONNECTIONS CHECK FOR AMP DRAW ON REVERSING VALVE SOLENOID COIL FAULT IS IN COIL WIRING CHECK THE B AND COMMON TERMINALS FEEDING THE DEFROST CONTROL REVERSING MALFUNCTION VALVE SOLENOID TEST AND REPLACE COIL IF NECESSARY DEFROST RELAY IS ENERGIZED INDICATING POSSIBLE COIL IS DEFECTIVE REPLACE REVERSING VALVE IS DEFECTIVE REPLACE CHECK CIRCUIT BREAKER OR FUSES THERMOSTAT CALLING FOR HEATING WAIT FIVE MINUTES FOR COMPRESSOR TIME DELAY FAULT IS IN WIRING BETWEEN TRANSFORMER AND TERMINAL BLOCK SECONDARY CHECK INLET VOLTAGE ACROSS COMPRESSOR TIME DELAY FAULT IS IN WIRING BETWEEN TRANSFORMER AND TERMINAL BLOCK INDOOR FAN RUNS BUT COMPRESSOR OUTDOOR FAN DOES NOT START Troubleshooting Chart Heating Mode COMPRESSOR OUTDOOR FAN RUNS BUT INDOOR FAN DOES NOT START CHECK FOR 24 VOLTS BETWEEN X amp G ON TERMINAL BLOCK IF NO VOLTAGE BETWEEN X amp Y OR X amp G FAULT IS THERMOSTAT WIRE OR IF NO VOLTAGE IS INDICATED FAULT IS IN Wiring BETWEEN TERMINAL BLOCK amp RELAY CHECK COIL C amp G TERMINAL IF NO VOLTAGE BETWEEN X amp R ON BUBBASE FAULT IS IN WIRING BETWEEN THERMOSTAT AND LOW VOLTAGE TERMINAL STRIP
18. T VOLTAGE ACROSS THERMOSTAT IF NO VOLTAGE IS FAULT IS IN WIRING COMPRESSOR TIME DELAY INDICATED FAULT IS BETWEEN IN WIRING BETWEEN TRANSFORMER AND TERMINAL BLOCK amp TERMINAL BLOCK RELAY CHECK COIL YES CHECK TO SEE IF PRIMARY SIDE IF 24 VOLTS IS AT 240 VOLTS BETWEEN X amp R ON E WENS A CHECK OUTLET VOLTAGE SUBBASE FAULT IS IN RON ON TIME DELAY AFTER WIRING BETWEEN SUBBASE WAITING 5 MINUTES THERMOSTAT AND LOW VOLTAGE THERMOSTAT TERMINAL STRIP amp WIRE WIRES BETWEEN CIRCUIT BREAKER AND TRANSFORMER 15 TRANSFORMER ARE Sone DEFECTIVE CHECK REPLACE IF NO VOLTAGE THE Y CIRCUIT IS THE COMPRESSOR YES CONTACTOR PULLED IN FAULT LIES IN INDOOR FAN MOTOR OR WIRING CONNECTION apoy 2 yey buljooysajqnoiy CHECK FOR 240 VOLT PRIMARY THEN TIME DELAY IS FAN RELAY IS CHECK DEFECTIVE DEFECTIVE COMPRESSOR REPLACE CAPACITOR COMPRESSOR OUTDOOR FAN MOTOR LEADS IS OUTDOOR FAN DEFECTIVE MOTOR REPLACE UNIT STARTS 5 CYCLES AND GOES INTO COMPRESSOR TIME DELAY CHECK INDOOR AIR FILTER AND DUCT SYSTEM FOR AIR RESTRICTION UNIT OPERATES BUT ONLY IN COOLING MODE CHECK FOR 24 VOLTS BETWEEN B NOTING WILL START CHECK FOR 24 VOLTS BETWEEN X amp R ON LOW VOLTAGE TERMINAL BLOCK amp X ON LOW VOLTAGE TERMINAL BLOCK CHECK FOR 24 VOLTS ON TRANSFORMER REMOVE THERMOSTAT AND CHECK CHECK REVERSING VALVE COIL FOR 24 WIRE I
19. THE TERMINALS WITH A SCREWDRIVER Capacitor Connections The starting winding of a motor can be damaged by a shorted and grounded running capacitor This damage usually can be avoided by proper connection of the running capacitor terminals From the supply line on a typical 230 volt circuit a 115 volt potential exists from the R terminal to ground through a possible short in the capacitor However from the S or start terminal a much higher potential possibly as high as 400 volts exists because of the counter EMF generated in the start winding Therefore the possibility of capacitor failure is much greater when the identified terminal is connected to the S or start terminal The identified terminal should always be connected to the supply line or R terminal never to the S terminal When connected properly a shorted or grounded running capacitor will result in a direct short to ground from the R terminal and will blow the line fuse The motor protector will protect the main winding from excessive temperature Compressors The type of compressor used is the SCROLL compressor The Scroll compressor may easily be distinguished from a areciprocating compressor by its relatively tall and relatively small diameter round case Although the methods of testing and or checkout of both types of compressors is essentially the same the Scroll compressor differs from the reciprocating type compressor several ways First
20. URE SELECTOR White Rodgers 1F59 13 The White Rodgers thermostat has switches that control the anticipation setting The following illustrations and tables show the location of the switches and setting information SWITCH WIRE TERMINALS SYSTEM ANTICIPATION SWITCHES Terminal and Switch Location Shorter Cycles Lenger Cyrias Anticipation Selection Switch Settings applying power Table 1 First Stage Heat and Cool Anticipation Reference Approx Temperature Differential Heat Anticipation Reference Approx Temperature Differential The 260 is a basic heat cool thermostat with a set of mechanical contacts operated by a bimetal coil Accurate leveling is not a requirement for proper operation of this thermostat The thermostat controls are described below TEMPERATURE SELECTOR TURN KHOR Ne TN a THERMOMETER 1 L Fi laam aura F la 1 EI j FAN SWITCH Z SYSTEM SWITCH Robert Shaw CM 260 CAUTION Recheck the wiring to be certain proper terminals are connected before Improper wiring or installation may damage the thermostat Electric Strip Heaters Electric heat strips use electrical resistance to produce heat They normally use coils of nichrome wire to provide the resistance When electrical current flows through the coils the resistance of the coil p
21. at any time during the accumulation period such as may happen during an OFF cycle in mild weather the ACCUMULATED time will be lost i e counter is reset to zero An automatic defrost capability is provided in the system that will defrost the outdoor air coil wnen needed The defrost cycle is controlled by an ICM 300 time temperature control As described on Page 7 Defrost After the selected compressor run time is accumulated and a coil temperature of 33 3 degrees F is reached the Defrost Control initiates a defrost cycle by energizing the Defrost Relay The normally closed Defrost Relay contacts 4 5 open turning off the outdoor blower motor Relay contacts 1 2 open de energizing the Reversing Valve Solenoid The normally open Defrost Relay contacts 1 3 close energizing the Defrost Heater Relay turning on the electric heat After 10 minutes or a rise in coil temperature to 55 degrees F the defrost cycle will terminate When the defrost cycle is terminated the above actions are reversed The control will then begin accumulating time when if the sensor closes during the next run ON cycle Once initiated a defrost cycle may be terminated one of two 2 different ways 1 The first or Normal termination is based on coil temperature When the defrost sensor reaches its opening temperature indicating a fully defrosted coil it will open deselecting the circuits that caused the unit to change over in
22. aters ONLY in operation to obtain watts Kilowatts are than obtained by dividing by 1000 EXAMPLE Measured voltage to unit heaters is 230 volts Measured Current Draw of strip heaters is 20 0 amps 230 X 20 0 4600 4600 1000 4 6 Kilowatts 4 6 x 3413 15700 Supply Air 95 F Return Air 75 Temperature Rise 20 20 X 1 08 21 6 15700 727 21 6 Condenser Fan Motors The INSIDER VERT I PAK B Series units use a single speed permanent split capacitor motor direct drive Different size HP motors and or wheels are used on different models to obtain the required heat transfer Capacitors Many motor capacitors are internally fused Shorting the terminals will blow the fuse ruining the capacitor A 20 000 ohm 2 watt resistor can be used to discharge capacitors safely Remove wires from capacitor and place resistor across terminals Capacitor Check With Capacitor Analyzer The capacitor analyzer will show whether the capacitor is open or shorted It will tell whether the capacitor is within its microfarads rating and it will show whether the capacitor is operating at the proper power factor percentage The instrument will automatically discharge the capacitor when the test switch is released WARNING HAZARD OF SHOCK AND ELECTROCUTION A CAPACITOR CAN HOLD A CHARGE FOR LONG PERIODS OF TIME A SERVICE TECHNICIAN WHO TOUCHES THESE TERMINALS CAN BE INJURED NEVER DISCHARGE THE CAPACITOR BY SHORTING ACROSS
23. commended setting is 60 minutes Test the defrost control as follows a place a jumper from transformer 24VAC to the 24VAC terminal at the control board to simulate closed contacts b with the unit running in the heat mode short the test pins until a click is heard remove the short immediately Outdoor fan should shut off reversing valve should switch and heater contactor s should engage c turn off the unit and remove the test jumper from the 24VAC terminals Affix these instructions close to the unit for future reference Design A units refer to figure 3 for wire diagram TO THERMOSTAT LEGEND LOW VOLTAGE FIELD WIRING LOW VOLTAGE CONTROL WIRING HIGH VOLTAGE WIRING L2 HEATER R V SOLENOID we GREEN YELLOWS oe ees St eee eee z z S amp e E BLUE S WHITES me ERR a INDOOR 455 FAN gt MOTOR 82 1 FREEZE UP THERMOSTAT U LO PRESSURE SWITCH C HI PRESSURE SWITCH DEFROST SENSOR HEATER 1 HEATER 2 Figure 2 INSIDER and Ser ies Service Manual Table of Contents Introduction Model Number Identification Guide Serial Number Identification Guide General Description Refrigerant System Operation Sequence of Operation Air Circulatio
24. companied by a REDUCTION in airflow External Static Pressure is affected by two 2 factors 1 Resistance to Airflow as already explained 2 Blower Speed Changing to a higher or lower blower speed will raise or lower the External Static Pressure accordingly These affects must be understood and taken into consideration when checking External Static Pressure Airflow to insure that the system is operating within design conditions Operating a system with insufficient or excessive airflow can cause a variety of different operating problems Among these are reduced capacity freezing evaporator coils premature compressor and or heating component failures etc System airflow should always be verified upon completion of a new installation or before a change out compressor replacement or in the case of heat strip failure to insure that the failure was not caused by improper airflow Checking External Static Pressure The airflow through the unit can be determined by measuring the external static pressure of the system and consulting the blower performance data for the specific INSIDER and VERT I PAK B Series unit Set up to measure external static pressure at the supply and return air 2 Drill holes in the supply duct for pressure taps pilot tubes or other accurate pressure sensing devices 3 Connect these taps to a level inclined manometer or Magnehelic gauges 4 Ensure the coil and filter are clean and that
25. conversion scales on their face The Subcooling method can be used when a partial charge remains in the unit and it is not desirable to remove the entire charge To charge by the Subcooling method the requires the following steps 1 Connect refrigerant gauges to service access ports start unit and allow to run for several minutes until system pressures stabilize 2 While waiting for pressures to stabilize measure Outdoor Dry Bulb temperature must be between 65 and 115 F 3 Measure and record liquid line temperature as close to condenser coil OUTLET as practical 4 Usingthe R 22 temperature conversion scale on the High Side gauge if so equipped or a pressure temperature chart convert liquid pressure to saturation temperature 5 Subtract measured liquid temperature from the converted saturation temperature the result is Subcooling 6 Compare calculated subcooling with allowable range 8 F to 12 F of subcooling 20 7 lf calculated subcooling is HIGHER than the allowable range gradually REMOVE recover refrigerant vapor from suction side of system Recheck Subcooling periodically while removing refrigerant and discontinue removing refrigerant when allowable range has been reached 8 If calculated Subcooling is LOWER than the allowable range gradually ADD refrigerant vapor to the suction side of system The TXV is not adjustable If allowable subcooling cannot be obtained by adding or r
26. cted Indoor Blower Air Flow INSIDER and VERT I PAK B Series units use a single speed permanent split capacitor motor direct drive Different size HP motors and or different diameter blower wheels are used in different models to obtain the required airflow Blower Wheel Inspection Visually inspect the blower wheel for the accumulation of dirt or lint since they can cause reduced airflow Clean the blower wheel of these accumulations If accumulation cannot be removed it will be necessary to remove the blower assembly from the unit for proper wheel cleaning Cooling A nominal 400 350 450 allowable CFM per ton of airflow is required to insure proper system operation capacity and efficiency Factory blower motors should provide the proper airflow for the size cooling capacity of the unit when connected to a properly sized duct system External Static Pressure External Static Pressure can best be defined as the pressure difference drop between the Positive Pressure discharge and the Negative Pressure intake sides of the blower External Static Pressure is developed by the blower as a result of resistance to airflow Friction in the air distribution system EXTERNAL to the INSIDER VERT I PAK B Series cabinet Resistance applied externally to the INSIDER and VERT I PAK B Series i e duct work coils filters etc on either the supply or return side of the system causes an INCREASE in External Static Pressure ac
27. d Room Thermostats Room thermostats are available from several different manufacturers in a wide variety of styles They range from the very simple bimetallic type to the complex electronic set back type In all cases no matter how simple or complex they are simply a switch or series of switches designed to turn equipment or components ON or OFF atthe desired conditions An improperly operating or poorly located room thermostat can be the source of perceived equipment problems A careful check of the thermostat and wiring must be made to insure that it is not the source of problems Location The thermostat should not be mounted where it may be affected by drafts discharge air from registers hot or cold or heat radiated from the sun or appliances The thermostat should be located about 5 Ft above the floor in an area of average temperature with good air circulation Close proximity to the return air grille is the best choice Mercury bulb type thermostats MUST be level to control temperature accurately to the desired set point Electronic digital type thermostats SHOULD be level for aesthetics Measuring Current Draw e Thermostat Sub base Ammeter Thermostat Location THERMOSTAT Heat Anticipators Heat anticipators are small resistance heaters wired in SERIES with the W circuit and built into most electromechanical thermostats Their purpose is to prevent wide swings in room tem
28. e Timer Anti cycle Timer Scroll Compressor Models Some older models are equipped with an electronic Anti Cycle timer This timer is required to prevent the possibility of the scroll compressor running in reverse rotation due to a momentary power interruption The anti cycle timer is essentially a delay on break timer which prevents the compressor contactor from reenergizing for a period of 5 minutes if the power to itis interrupted This delay provides sufficient time for the compressor to come to a complete stop before being reenergized preventing the compressor from starting in reverse rotation If defective however it will not complete the circuit to the compressor contactor The anti cycle timer is not used on new INSIDER Vert Pak units The IF59 13 thermostat has a built in anti cycle feature Defrost Typical Defrost Sensor When operating the heat pump in 1st Stage Heating refrigerant flow discharge gas is being directed by the reversing valve to the INDOOR coil making it the CONDENSER Consequently the OUTDOOR coil is then acting as the EVAPORATOR Operating an evaporator coil in low outdoor ambient temperatures such as would be present when heating is required will cause the EVAPORATOR outdoor coil to develop frost Left unchecked the frost would continue to build to the point of totally blocking the coil severely reducing heat transfer and consequently the heating capacity of the unit Ty
29. e phase PSC compressor motor the highest value will be from the start to the run connections S to R The next highest resistance is from the start to the common connections S to C The lowest resistance is from the run to common C to R Before replacing a compressor check to be sure it is defective Check the complete electrical system to the compressor and compressor internal electrical system check to be certain that compressor is not out on internal overload Complete evaluation of the system must be made whenever you suspect the compressor is defective If the compressor has been operating for sometime a careful examination must be made to determine why the compressor failed Recommended procedure for compressor replacement NOTE Be sure power source is off then disconnect all wiring from the compressor 1 Be certain to perform all necessary electrical and refrigeration tests to be sure the compressor is actually defective before replacing 2 Recover all refrigerant from the system PROPER HANDLING OF RECOVERED REFRIGERANT ACCORDING TO EPA REGULATIONS IS REQUIRED Do not use gauge manifold for this purpose if there has been a burnout You will contaminate your manifold and hoses 3 After all refrigerant has been recovered disconnect suction and discharge lines from the compressor and remove compressor Be certain to have both suction and discharge access tubes open to atmosphere 4 Carefully pour a
30. emoving refrigerant the TXV is suspect Sensing External Equalizer Non Adjustable TXV Reversing Valve Description Operation The Reversing Valve controls the direction of refrigerant flow to the indoor and outdoor coils It consists of a pressure operated main valve and a pilot valve actuated by a solenoid plunger The solenoid is energized during the heating cycle only The reversing valve used in INSIDER VERT I PAK B Series systems are 2 position 4 way valves The single tube on one side of the main valve body is the high pressure inlet to the valve from the compressor The center tube on the opposite side is connected to the Low pressure suction side of the system The other two are connected to the indoor and outdoor coils Small capillary tubes connect each end of the main valve cylinder to the A and B ports of the pilot valve A third capillary is a common return line from these ports to the suction tube on the main valve body Four way reversing valves also have a capillary tube from the compressor discharge tube to the pilot valve The piston assembly in the main valve can only be shifted by the pressure differential between the high and low sides of the system The pilot section of the valve opens and closes ports for the small capillary tubes to the main valve to cause it to shift NOTE System operating pressures must be near normal before valve can shift PILOT SOLENOID VALVE FROM VALVE DISCHARGE
31. he frost free thermostat opens reversing the above actions and returning the unit to normal heat pump mode operation Emergency Heat The EM HEAT setting provides for the use of the electric auxiliary heat in the event of a malfunction ofthe heat pump system NOTE For economical reasons the EM HEAT mode should only be used when necessary With the thermostat set on EM HEAT or EMER and the FAN switch set on AUTO a drop in room temperature causes the upper mercury switch to make a 24 volt signal on the G thermostat conductor energizing the indoor blower post purge control and turning on the indoor air blower It also causes a 24 volt signal on the W thermostat terminal energizing the electric heat contactor s turning on the electric heat Arise in room temperature causes the upper mercury switch to break the 24 volt signal on the G thermostat conductor starting the timer of the post purge control 60 second delay to turn off the indoor air blower It also causes the loss of the 24 volt signal on the W thermostat terminal de energizing the electric heat contactor s turning off the electric heat Electrical Supply WARNING Electrical shock hazard Turn OFF electric power at fuse box or service panel before making any electrical connections and ensure a proper ground connection is made before connecting line voltage Failure to do so can result in property damage personal injury and or death CONTROL WIRING LOW VOLTA
32. heater relay added Refer to wiring diagram on page 4 c Units falling after date code 98020066 refer to wiring diagram in the unit See figure 2 SECTION 3 PROCEDURE WARNING MORE THAN ONE DISCONNECT MAY BE REQUIRED TO DE ENERGIZE THE UNIT TO PREVENT RISK OF ELECTRICAL SHOCK OPEN ALL REMOTE DISCONNECTS BEFORE SERVICING THIS APPLIANCE 4 t 5s INT NOTE FOR UNIT DESIGNS A B THIS IS NOT AN IDENTICAL REPLACMENT THEREFORE THE WIRING WILL CHANGE FROM THE ORIGINAL 1 Turn off all electrical power to the unit at the home s main service panel 2 Remove the upper front panel and the controi box access cover from the heat pump 3 Remove and discard the red wire between the transformer and the old control board designs A B See figure 1 page 3 4 Forunit design B requiring the additional relay find a suitable location and mount the relay with the screws provided 5 Reach behind the control box and cut the sensor wires that are molded into the old defrost board 2 blue and 1 white 2 red and 1 white and pull those wires out Disconnect the remaining leads from the old defrost control These leads are indicated as broken lines in figure 1 Remove old control 6 Mount the new defrost control in the exact location the old one was removed from 7 Bring the two leads of the new defrost sensor into the control box Connect one of the leads to the 24 volt terminal of the transformer and connect the ot
33. her lead to the new defrost control at one of the terminals labeled 24VAC Reconnect the leads disconnected in step 5 to the new control Note The old control has two common terminals whereas the new control has one The two commons must be tied together or the reversing valve common will need to be relocated Units requiring the additional relay will wire as follows a remove the brown wire from pin 3 of the defrost relay and move it to pin 3 of the defrost heater relay b using one of the new wires connect one end to pin 1 of the defrost heater relay and the other end to the hold terminal of the new defrost controi with another new wire place one end on pin 3 of the defrost relay and the other end of this wire on coil terminal A of the defrost heater relay d place one end of the third and final wire on coil terminal B of the defrost heater relay and the other end of this wire on transformer common 10 Refer to figure 4 for proper location of the defrost 11 12 IF YOU HAVE ANY QUESTIONS REGUARDING THESE SERVICE INSTRUCTIONS OR NEED TECHNICAL ASSISTANCE PLEASE CALL TOLL FREE 1 800 807 7066 extension 3 sensor according to unit model and coil design Secure the sensor to the U Bend with one of the tie wraps provided Wrap the sensor with the piece of presstite provided to prevent the sensor from being influenced by surrounding air temperatures Check the new control s run time jumper Re
34. iagram 56 Air Conditioners with Water Coil 67 All Standard Heat Pump Wiring Diagram 78 Frost Free Heat Pump Wiring Diagrams 28 29 Time Delay Relay Wiring Diagram 30 Troubleshooting Chart Cooling Mode 31 Troubleshooting Chart Heating Mode 32 Refrigerant System Diagnosis Cooling 33 Refrigerant System Diagnosis Heating 34 Introduction This service manual is designed to be used in conjunction with the installation manuals provided with each air conditioning system component Air conditioning systems consist of BOTH an evaporator indoor section and a condenser outdoor section in one closed system and a room thermostat Electric strip heaters are also considered part of the system This service manual was written to assist the professional HVAC service technician to quickly and accurately diagnose and repair any malfunctions of this product IMPORTANT It will be necessary for you to accurately identify the unit you are servicing so you can be certain of a proper diagnosis and repair See Unit Identification The information contained in this manual is intended for use by a qualified service technician who is familiar with the safety procedures required in installation and repair and who is equipped with the proper tools and test instruments Installation or repairs made by unqualified persons can result in hazards subjecting the unqualified person making such repairs to the risk of injury or electrical shock which can be se
35. ig at which time it will close again auto reset completing the circuit to the compressor contactor Low Pressure Switch The low pressure switch is a Normally Open pressure operated switch Automatic Reset wired in series with the compressor contactor The switch closes at a Nominal 15 5 psig of pressure in the refrigerant system completing the circuit to the compressor contactor The switch will remain closed until the system pressure drops below a Nominal 3 psig at which time it will open breaking the circuit to the compressor contactor Compressor Checks Locked Rotor Voltage L R V Test Locked rotor voltage L R V is the actual voltage available at the compressor under a stalled condition Single Phase Connections Disconnect power from unit Using a voltmeter attach one lead of the meter to the run R terminal on the compressor and the other lead to the common C terminal of the compressor Restore power to unit CAUTION Make sure that the ends of the lead do not touch the compressor shell since this will cause a short circuit Determine L R V Startthe compressor with the voltmeter attached then stop the unit Attempt to restart the compressor within a couple of seconds and immediately read the voltage on the meter The compressor under these conditions will not start and will usually kick out on overload within a few seconds since the pressures in the system will not have had time to equalize
36. n Cooling Heating Defrost Emergency Heat Electrical Supply Supply Circuit Supply Voltage Control Wiring Electrical Ground Room Thermostats Location Heat Anticipators Setting the Heat Anticipator Electric Strip Heaters Indoor Blower Air Flow Blower Wheel Inspection Cooling External Static Pressure Checking External Static Pressure Checking Approximate Airflow Electric Heat Strips Condenser Fan Motors Capacitors Capacitor Check With Capacitor Analyzer Capacitor Connections Compressors Operating Noise Level Compressor Contactor Anti cycle Timer Defrost oO O O c4 S S NS S O O Defrost Control Operation Testing Defrost Mode Of Operation Troubleshooting High Pressure Switch Low Pressure Switch Compressor Checks Locked Rotor Voltage L R V Test Single Phase Connections Determine L R V Amperage L R A Test Single Phase Running and L R A Test Internal Overload Checking the Internal Overload Single Phase Resistance Test Procedure for Compressor Replacement Expansion Valves Refrigerant Charging Method of Charging Subcooling Method Reversing Valve Description Operation Electrical Circuit and Coil Testing Coil Checking the Reversing Valve Procedure for Changing Reversing Valve 21 22 INSIDER Chassis Specifications 22 B Series Chassis Specification 23 Wiring Diagram Index 24 All Standard Air Conditioners Wiring D
37. ng the UNE subcooling method as explained 20 HOT FROM COMPRESSOR DISCHARGE REVERSING VALVE IN COOLING MODE gt INSIDER CHASSIS SPECIFICATIONS J Po Ge ewm me ows x SER n n mn T s P ss T s J rirpu 1050 i 1 righ Temp COP ELECTRICAL DATA 522 250520 Hard Wired PHYSICAL DATA Unt eight Shipping Weight Lbs 400 Rated in accordance with ARI standard 240 and Department of Energy test standards Ratings are net values based on 230 volt operation Auxiliary electric resistance heat is not included Ratings are based Cooling Standard 80 F db 67 F wb indoor entering air temperature95 F db air entering the outdoor coil Hi Temp Heating Standard 70 F db indoor entering air temperature47 F db 43 F wb air entering the outdoor coil Lo Temp Heating Standard 70 F db indoor entering air temperature17 F db 15 F wb air entering the outdoor coil For 208 230 60 1 units the maximum operating voltage is 253 the minimum operating voltage is 197 Models CDHP18 and CHDP25 are available with 5KW or 10KW auxiliary electric resistance heat Models CDHP29 CDHP35 and CDHP42 are available with either 10KW 15 KW auxiliary electric resistance heat Model CDHBA6 is available with either 15KW or 20 KW auxiliary electric resistance heat 5KW and 10 KW heat systems use one 1 circuit breaker 15KW and 20 KW heat systems
38. ntering the evaporator coil As it enters the evaporator coil a larger area and lower pressure allows the refrigerant to expand and lower its temperature heat intensity This expansion is often referred to as boiling Since the units blower is moving indoor air across the finned surface of the evaporator coil the expanding refrigerant absorbs some of that heat This results in a lowering of the indoor air temperature hence the cooling effect The expansion and absorbing of heat cause the liquid refrigerant to evaporate i e change to a gas Once the refrigerant has been evaporated it is heated even further by the air that continues to flow across the evaporator coil The particular system design determines at exactly what point in the evaporator the change of state i e liquid to gas takes place In all cases the refrigerant must be totally evaporated changed to a gas before leaving the evaporator coil The low pressure suction created by the compressor causes the refrigerant to leave the evaporator through the suction line as a COOL low pressure vapor The refrigerant then returns to the compressor where the cycle is repeated SEQUENCE OF OPERATION Air Circulation When the thermostat is set with the FAN switch set to ON and the SYSTEM switch is set to OFF the heat pump is in air circulation mode While the thermostat is set this way a 24 volt signal is on the G thermostat terminal energizing the blower cont
39. onstant Superheat in the coil it is controlling regardless of loading conditions It accomplishes this by OPENING allowing more refrigerant flow to the coil or CLOSING allowing less refrigerant to flow to the coil The extent to which the valve opens or closes is based on the temperature sensed by the temperature sensing bulb Thls that the sensing bulb MUST be in good contact with the suction line to insure proper operation Expansion valves used in the evaporator coils of INSIDER VERT I PAK B Series units areNONADJUSTABLE expansion valves Their Superheat setting CANNOT be changed When replacing expansion valves a factory authorized TXV must be used Refrigerant Charging Proper refrigerant charge is essential to proper unit operation Operating a unit with an improper refrigerant charge will result in reduced performance capacity and or efficiency Accordingly the use of proper charging methods during servicing will insure that the unit is functioning as designed and that its compressor will not be damaged Method Of Charging The acceptable method for charging INSIDER VERT I PAK B Series is the Weighed in Charge Method The weighed in charge method is applicable to all units It is the preferred method to use as it is the most accurate The weighed in method should always be used whenever a charge is removed from a unit such as for a leak repair compressor replacement or when there is no refrigerant charge left in the uni
40. perature during system operation in the HEATING mode Since they are wired in series the W circuit will open if one burns out preventing heat operation The heat anticipator provides a small amount of heat to the thermostat causing it to cycle turn off the heat source just prior to reaching the set point of the thermostat This prevents exceeding the set point In order to accomplish this the heat output from the anticipator must be the same regardless of the current flowing through it Consequently some thermostats have an adjustment to compensate for varying current draw in the thermostat circuits The proper setting of heat anticipators then is important to insure proper temperature control and customer satisfaction A Heat anticipator that is set too low will cause the heat source to cycle prematurely possibly never reaching set point A heat anticipator that is set too high will cause the heat source to cycle too late over shooting the set point Setting the Heat Anticipator The best method to obtain the required setting for the heat anticipator is to measure the actual current draw in the control circuit W using a low range 0 2 0 Amps Ammeter After measuring the current draw simply set heat anticipator to match that value If a low range ammeter is not available a Clamp on type ammeter may be used as follows 1 Wrap EXACTLY ten 10 turns of wire around the jaws of aclamp on type ammeter 2 Connect one
41. pical Defrost Control Board To insure that this does not happen some means of Defrosting the unit is required All INSIDER and VERT I PAK B units use either an active defrost or passive defrost design Check the Model Number Guide to identify which design you are working with Defrost Control Operation Active Defrost An Electromechanical Defrost Coil Temperature Sensor is used with all of the various defrost controls This sensor is a Normally Open switch wired in series with either the R terminal or the C terminal The sensor closes when coil temperature conditions have been met When closed the sensor completes a circuit to components within the control board itself which then begins Accumulating keeping track of compressor run time Consequently if the sensor NEVER closes the unit will NEVER Defrost Defrost intervals frequency are field selectable 30 60 90 Minutes The frequency may be changed by moving positioning the jumper or shunt to a different terminal i e 30 minutes 60 minutes and 90 minutes Defrost intervals should be set to the LONGEST interval that will still allow the coil to completely defrost during one defrost cycle With the desired defrost interval selected the control will initiate a defrost cycle whenever it ACCUMULATES this amount of compressor run time The defrost coil temp sensor MUST remain closed during this accumulation Period If the defrost sensor opens
42. r the overload to reset Checking the Internal Overload A reading of infinity between any two terminals MAY indicate an open winding If however a reading of infinity is obtained between amp R and C amp S accompanied by a resistance reading between S amp R an open internal overload is indicated Should you obtain this indication allow the compressor to cool May take up to 24 hours then recheck before condemning the compressor If an open internal overload is indicated the source of its opening must be determined and corrected Failure to do so will cause repeat problems with an open overload and or premature compressor failure Some possible causes of an open internal overload include insufficient refrigerant charge restriction in the refrigerant circuit and excessive current draw NOTE OHM Figures are for examples only not actual values for the compressor 3 65 OHMS RESISTANCE RESISTANCE EQUALS RESISTANCE Stoc RtoC StoR Single Phase Resistance Test Remove the leads from the compressor terminals and set the ohmmeter on the lowest scale R x 1 Touch the leads of the ohmmeter from terminals common to start C to S Next touch the leads of the ohmmeter from terminals common to run C to R Add values C to S and C to R together and check resistance from start to run terminals S to R Resistance S to R should equal the total of C to S and C to R In a singl
43. rature of the outdoor coil to do so No heat is supplied by the unit to remove the frost amp ice When the frost free thermostat senses a temperature of 33 degrees or 3 degrees the compressor is locked out The outdoor fan continues to run allowing outdoor air to help speed the defrosting process Keep in mind however that the colder the outdoor temperature is the longer it will take for frost and ice to melt from the outdoor coil When the frost free thermostat senses a rise in the temperature of the outdoor coil to 53 degrees or 5 5 degrees the passive defrost cycle is complete The compressor will now be able to run to provide heat to the space Testing Defrost Operation Passive Defrost The Frost Free Thermostat is mounted to the outdoor coil Itis a saddle type sensor using a snap type strap to secure itto areturn bend on the outdoor coil The thermostat switch contacts are normally open and will close on a fall in temperature Two leads are permanently connected to the thermostat One lead connects to the coil of the frost free relay On earlier model units the other lead connects to R on the low voltage transformer Later model units have this lead connected to terminal 4 on the frost free relay Disconnect power to the unit Keep in mind that more that one disconnect may be required Install a jumper between the two leads of the frost free thermostat Restore power to the unit The compressor sho
44. rious or even fatal not only to them but also to persons being served by the equipment If you install or perform service on equipment you must assume responsibility for any bodily injury or property damage which may result to you or others Friedrich Air Conditioning Company will not be responsible for any injury or property damage arising from improper installation service and or service procedures MODEL NUMBER P118B10501A DESIGN SERIES c Model Number Identification Guide C Standard Efficiency E High Efficiency D Down Flow U Up Flow AC Air Conditioning H Heat Pump Series P B NOMINAL CAPACITY BTUh 18 18 000 22 22 000 24 24 000 25 25 000 29 29 000 35 35 000 36 36 000 48 48 000 VOLTAGE 208 230V 1Ph 60 Hz Active Defrost 208 230V 1Ph 60Hz Passive Defrost FILTER TYPE 0 Front grille w filter CDHP models 1 No grille drop in rack w filter 2 Left side RA duct w o filter 3 Front RA duct w o filter ELECTRIC HEATER SIZE Nominal KW size 05 2 5 0 KW 10 2 10 0 KW 15 2 15 0KW VERE I PAK Model Number Identification Guide MODEL NUMBER V V Vertical Series E Cooling with or without electric heat H Heat Pump DESIGN SERIES NOMINAL CAPACITY BTUh 24 24 000 30 30 000 36 36 000 42 42 000 48 48 000 60 60 000 VOLTAGE K 208 230V 1Ph 60Hz 24 K 10 ENGINEERING CODE DEFROST TYPE RT Active Defrost FF Pas
45. rminal to check to verify ifthe controlis performing the necessary switching functions If the control performs the necessary switching functions the problem is NOT in the defrost control it is EXTERNAL to the control An electromechanical defrost coil temperature sensor is used on ALL units This sensor is a NORMALLY OPEN electrical switch wired in series with the defrost control board Depending upon the particular model and or control used it may be wired in series with either the R circuit or the C circuit to the board The sensor CLOSES when its temperature drops below a predetermined level completing the circuit to the defrost board to begin ACCUMULATING compressor run time The sensor OPENS during defrost at another predetermined level to TERMINATE the defrost cycle The sensor can also OPEN during an OFF cycle in warmer outdoor ambient conditions which will RESET zero out any time that has been accumulated on the defrost control board If the defrost sensor does NOT open and close it must be replaced The sensor is designed to close at 33 3 degrees F and open at 53 F 5 When replacing the defrost sensor BE ABSOLUTELY CERTAIN to reinstall the replacement sensor in the EXACT LOCATION of the removed sensor Failure to do so may create problems with improper defrosting of the unit Passive Defrost Units which employ the Passive method for defrosting the outdoor coil depend upon the rising of the tempe
46. roduces a specific amount of heat Proper airflow across strip heaters is essential to insure proper operation and life expectancy During operation the elements will produce a dull orange glow Insufficient airflow will cause elements to overheat producing a very bright orange glow and cycle on limit switch or possibly Heaters available several sizes wattage Normally heaters larger then 10 KW 10 kilowatts are divided into increments with one or two increments i e 5 or 10 KW controlled by a single relay which energizes a contactor Strip heaters may be checked using one of several methods During operation Calling for Heat a clamp on ammeter may be used to check the current draw of each individual increment to verify its operation At 240 Volts nominal a current draw of approximately 20 Amps should be indicated for each 5 KW If no current draw is indicated the heater is notoperating This may be due to defective relay or contactor an open broken element tripped open breaker etc These conditions then may be checked with the power OFF using ohmmeter They may also be checked being very careful with the power ON by using a voltmeter All component parts of strip heater assemblies are field replaceable If the entire heater package is removed for servicing i e component replacement extreme care should be used when reinstalling the heater package that all wiring is properly conne
47. rol turning on the indoor air blower The blower will run continuously until the setting is changed Cooling When thermostat is set for cooling mode SYSTEM switch set to COOL and FAN switch set to AUTO a rise in room temperature will make a 24 volt signal on the G thermostat terminal to the post purge control turning on the indoor air blower It also causes a 24 volt signal on the Y thermostat conductor to the high and low pressure switches energizing the compressor contactor turning on the compressor and outdoor air blower A drop in room temperature will break the 24 volt signal on the Y thermostat terminal de energizing the compressor contactor turning off the compressor and outdoor air blower It also causes the loss of the 24 volt signal on G thermostat terminal starting the timer of the post purge control 60 second delay to turn off the indoor air blower Heating With the thermostat set to heating mode SYSTEM switch set to HEAT and FAN switch set to AUTO a drop in the room temperature will make a 24 volt signal on the G thermostat terminal to the post purge control turning on the indoor air blower It also makes a 24 volt signal on the Y thermostat terminal through the high pressure switch and low pressure switch energizing the compressor contactor turning on the compressor and outdoor air blower The reversing valve solenoid coil will be energized through the B terminal when the thermostat is set to the hea
48. sive Defrost ELECTRIC HEATER SIZE Nominal KW size 05 2 5 0 KW 20 20 000 KW 10210 0KW 25 25 000 KW 15 15 0 KW Serial Number Identification Guide SERIAL NUMBER Year Manufactured 00001 PRODUCTION RUN NUMBER Month Manufactured 01 Jan 04 Apr 02 Feb 05 May 03 Mar 06 Jun 10 Oct 11 Nov 12 Dec 07 Jul 08 Aug 09 Sep GENERAL DESCRIPTION INSIDER and VERT I PAK B Series models are self contained indoor heating and cooling systems This means that all of the components for heating and cooling are in a single package INSIDER and VERT I PAK B Series units are manufactured as air conditioners with electric heat as well as heat pumps These units very similar to their heat pump counterparts with the main difference being in the control box components and the air conditioners do not have reversing valves Basically everything else is the same The cabinets are the same the major components are the same as is their general locations in the cabinet FODOR AIR SUPPLY i CHL ELEC TEE HEAT OPTIMAL 1 S an INCE BLOWER SDE RETURN n i 1 S4 X DV X 4 a AR EXHAUST AJH gt I 4 od he CATO NETUN E AIR ATA Duro BLOEN ERP SSS OM VALVE OUTDCOSR CHL C Dana E S REVERSING VALVE Heal Perr CONDENRATE Ce B SERIES UPFLOW MODELS OUTONA
49. st Free Heat Pumps Passive Defrost Early Models 230V 1PH 60H SUPPLY COMPRESSOR CONTACTOR COMPRESSOR INCLUDED ON ALL OPTIONAL NOT UNITS COMPRESSOR CONTACTOR 12 2 12 AUX OPTIONS PRI 230 VOLTS TERMINAL BLOCK FROST FREE THERMOST 28 Wiring Diagram Frost Free Heat Pumps Passive Defrost Later Models 230V 60HZ 1 PH SUPPLY COMPRESSOR COMPRESSOR CONTACTOR Ll2 AUX HEATER OPTIONS PRI 280 VOLTS 0000 0000 SEC 24 VOLTS PRESSURE LOW SWITCH FREEZE UP PRESSURE THERMOSTAT FROST FREE RELAY FROST FREE THERMOST FAN RELAY Passive Defrost Later Models 29 Wiring Diagram Time Delay Relay COMPRESSOR CONTACTOR PRESSLIRE SWITCH COM MH FIVE MINUTE Piers PRESSURE SWITCH PROM THERPAGISEAT F CORT ZT 30 Troubleshooting Chart THERMOSTAT CALLING FOR COOLING Cooling Mode WAIT FIVE MINUTES FOR COMPRESSOR TIME DELAY NOTHING WILL START CHECK FOR 24 INDOOR FAN RUNS BUT COMPRESSOR COMPRESSOR OUTDOOR FAN RUNS BUT VOLTS BETWEEN X AND R ON LOW OUTDOOR FAN DOES NOT START INDOOR FAN DOES NOT START CHECK FOR VOLTAGE TERMINAL BLOCK 24 VOLTS BETWEEN X amp G ON TERMINAL BLOCK YES CHECK FOR 24 VOLTS BETWEEN X amp Y ON NO CHECK VOLTAGE ACROSS CHECK FOR 24 VOLTS ON TRANSFORMER SECONDARY YES IF NO VOLTAGE BETWEEN X amp Y OR X amp G FAULT IS THERMOSTAT WIRE OR CHECK INLE
50. t INSIDER and VERT I PAK B Series units are equipped with a low pressure switch some older units did not include a low pressure switch connected to the units suction line or suction service valve The purpose of this switch is to prevent 19 damage to the compressor caused by operating with insufficient suction pressure Low suction pressure may be caused by insufficient refrigerant charge refrigerant restriction low airflow etc Operating the unit with insufficient suction pressure can cause a variety of problems within the unit Among these are overheating of the compressor windings the freezing of the evaporator coil To charge by this method requires the following steps 1 Recover Refrigerant in accordance with EPA regulations 2 Make necessary repairs to system 3 Evacuate system to 300 microns or less 4 Weigh in refrigerant with the property quantity of R 22 refrigerant 5 Startunit and verify performance Because INSIDERS VERT I PAK9 B Series units have expansion valves TVX the subcooling method is an acceptable method for charging Subcooling Method The Subcooling method is applicable to units equipped with THERMOSTATIC EXPANSION VALVE controlled evaporators Charging by the subcooling method is accomplished with the unit RUNNING It requires the use of ACCURATE refrigeration gauges electronic dry bulb thermometer and a pressure temperature chart if your refrigeration gauges do not have temperature
51. t position A further drop in the room temperature will make a 24 volt signal through the W thermostat terminal energizing the electric heat contactor bringing on the auxiliary electric heat Arise in the room temperature will break the 24 volt signal on the W thermostat terminal de energizing the electric heat contactor turning off the auxiliary electric heat A further rise in room temperature will break the 24 volt signal on the G thermostat conductor starting the timer of the post purge control 60 second delay to turn off the indoor air blower It also causes the loss of the 24 volt signal on Y thermostat conductor de energizing the compressor contactor turning off the compressor and outdoor air blower Defrost During normal operation in the heating mode frost amp ice may build up on the outdoor coil This frost amp ice must be removed periodically for the unit to operate properly The INSIDER amp VERT I PAK units employ either an active ora passivedefrost method to accomplish this To identify which method your unit employs Check the Model Number Identification Guides located at the beginning of this manual Active Defrost An active defrost cycle is initiated by the defrost control when the combination of the selected compressor run time and an outdoor coil temperature of 33 degrees or 3 degrees is reached When this occurs The defrost relay is energized e Contacts 4 amp 5 open de energizing the o
52. the Scroll compressor uses a pair of Scrolls one stationary one orbiting to compress and pump refrigerant through the system instead of the piston and valve arrangement found in a reciprocating compressor This design makes the Scroll compressor able to tolerate a certain amount of liquid refrigerant better than a reciprocating compressor Consequently crankcase heaters are not normally required on most scroll equipped models Scroll Compressor Operating Noise Level The operating noise characteristics of a scroll compressor also differ considerably from that of a reciprocating compressor If you are unfamiliar with the operating noise characteristics of a scroll compressor you should be absolutely certain that there is a problem with the compressor prior to replacing it For example a scroll compressor which is running in reverse rotation see anti cycle timer section on page 15 will apparently make an excessive amount of noise Compressor Contactor The compressor contactor is a Normally Open Double Pole Relay which when energized closes to complete the line voltage circuit to the compressor and outdoor fan motor Electrical Shock Hazard Disconnect power at fuse box or service panel before performing any service on the unit Failure to follow this warning can result in property damage personal injury and or death The contactor coil is energized on a call for COOLING AND HEATING from the room thermostat
53. to the defrost mode of operation This causes the second stage heat to be deenergized the outdoor fan to be reenergized and the reversing valve to shift back into the HEATING position 2 The second type of termination for a defrost is a TIMED forced termination In the event that the defrost sensor DOES NOT open within 10 minutes the control will terminate the defrost cycle and return to normal 1st stage heating operation Some of the reasons which might cause the sensor NOT to open during a normal defrost cycle are defrost interval set TOO LONG refrigerant circuit problems i e under charge restriction etc or a sensor which is mechanically stuck closed Testing Defrost Mode Of Operation Active Defrost The basic procedure for testing ALL of the defrost controls used in this series is nearly identical with relatively few variations exceptions as noted As previously stated the defrost Coil Temperature sensor MUST be closed BEFORE ANY UNIT can initiate a defrost cycle A closed defrost sensor can be simulated by jumpering across the defrost sensor The exact terminal identification s and or locations the defrost coil temp sensor is wired across may vary Check the wiring diagram for your particular unit to determine WHERE to place the jumper Once the defrost sensor is closed the Timing function of the board will begin Temperature first THEN time and a defrost cycle will be initiated when the selected
54. uld be locked out The electric strip heaters should be energized if the room thermostat is calling for heating Cycle the room thermostat to insure that the electric strip heaters do come on and off with the action of the thermostat The compressor should not run during this test When complete disconnect power to the unit and remove the jumper If you encounter a unit where frost or ice is present on the outdoor coil and the compressor is still running perform this simple test Should the compressor lockout with the jumper installed replace the frost free thermostat High Pressure Switch INSIDER and VERT I PAK B Series units are equipped with a high pressure switch The purpose of the high pressure switch is to prevent damage to the compressor which may occur as a result of operating under high discharge pressure conditions Some possible causes of high discharge include condenser fan motor failure excessive refrigerant charge air and non condensables in refrigerant circuit etc The high pressure switch is a Normally closed pressure operated switch automatic reset wired in series with the compressor contactor The switch will remain closed completing the circuit to the compressor contactor until the discharge pressure rises above a nominal 450 10 psig At this point the switch will open breaking the circuit to the compressor contactor The switch then will remain open until the pressure drops to a nominal 300 20 ps
55. utdoor blower e Contacts 4 amp 6 close energizing the drain line heater if equipped e Contacts 1 amp 2 open de energizing the reversing valve solenoid e Contacts 1 amp close energizing the defrost heater relay which energizes the electric heat strip strips When the outdoor coil temperature reaches 53 degrees or 5 5 degrees or 10 minutes passes the defrost control will terminate the defrost cycle reversing the above actions and returning the unit to normal heat pump mode operation Passive Defrost A passive defrost cycle is initiated when the outdoor coil temperature falls to 33 degrees or 3 degrees The frost free thermostat is responsible for determining this temperature It not only senses the outdoor coil refrigerant temperature it senses the outdoor entering airtemperature as well When this occurs e The frost free thermostat closes energizing the frost free relay coil e Contacts 4 amp 5 open de energizing the reversing valve solenoid e Contacts 1 amp 2 open de energizing the compressor contactor coil e Contacts 1 amp 3 close energizing the electric heater contactor coil when the room thermostat calls for heat When the room thermostat calls for heating the unit will now supply heat only by means of the electric strip heaters The compressor will remain locked out until the outdoor coil temperature rises to 53 degrees or 5 5 degrees When the above temperature is reached t
56. vent the main slide in the valve body from shifting If you determine this is the problem replace the reversing valve CAUTION Never energize the coil when it is removed from the valve as a coil burnout will result Procedure For Changing Reversing Valve 1 Recoverrefrigerant from system PROPER HANDLING OF RECOVERED REFRIGERANT ACCORDING TO EPA REGULATIONS IS REQUIRED 2 Remove solenoid coil from reversing valve If coil is to be reused protect from heat while changing valve 3 Unbraze alllines from reversing valve 4 Clean all excess braze from all tubing so that they will slip into fittings on new valve 5 Remove solenoid coil from new valve FROM OUTDOOR COIL TO COMPRESSOR SUCTION HOT BOTH THE SAME TEMERATURE BOTH THE SAME TEMERATURE FROM COMPRESSOR DISCHARGE REVERSING VALVE IN HEATING MODE 21 6 Protect new valve body from heat while brazing with plastic heat sink ThermoTrap or wrap valve body with TO OUTDOOR COIL wet rag TO COMPRESSOR SUCTION 7 Fitalllines into new valve and braze lines into new valve 8 Pressurize system with a combination of R 22 and nitrogen and check for leaks using a suitable leak detector Recover refrigerant per EPA guidelines ged ER E 9 Once the system is leak free install solenoid coil on new valve and charge the sealed system by weighing in the proper amount and type of refrigerant as shown on rating plate You can also charge the system usi
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