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RSD SERVICE MAN

1. THERMISTOR 240 60 1 Crank Case Heater is optional accessory 208 230 60 1 SCP LPC R2 34 U U U o JSE 24 25 26 lll 1 THERMISTOR HR1 HR2 HR3 Lwe i 20 fs 5 3 FAN COM 22 BLOWER COIL OUTDOOR UNIT Typical Wiring Schematic RSD A2 with BBC A2A blower gt a D 5 l lt 2 7 a x lt e gt OR DEATH DISCONNECT THE POWER BEFORE SERVICING SCHEMATICS 1 2 SCP e 3 i LPC 4 i i a Fam oN re 7 i 28 08 8 Thermostat shown for reference i i U U U only See the thermosta
2. z 5 2 x x 5 omme m FUSE cm a Sb STATUS INDICATOR 5 some 5 soma S 5 somme SPEED a soma a G 58 MIN N N wer U UO 5 JE BBC Control Board 11074204 Both the BBA and BBC control boards have an LED for indicating operating status The following table shows the codes that may be displayed by the LED LED SIGNAL If the LED indicates a continuous 1 2 second on 1 2 second off flash code then the control is in a normal operating mode and no adjustments need be made If the LED indicates 2 flashes thermistor and or board error then the thermistor connections should be verified first At 70 F the resistance of the thermistor should be 40 KW as temperature increases resistance decreases The resistance should be checked between the terminations of the thermistor leads at the control board making sure that the terminals are securely attached insuring a good connec tion Ifthe resistance is out of range false signals will be sent to the control board thus causing improper operation of the unit In that case the thermistor must be replaced If however the resistance is correct then the
3. Tes jee 9 installation instructions for i of ogo 24 25 26 additional information Pot Pd 5 5 5 10 i THERMISTOR 11 o 1 HR2 12 Po PG od i C o deea 6 3 62 usen OLOJO OOO I 2 5 16 i 12 PIN 22 maneconnanconccssasececenscste CONNECTOR FAN 22 17 FAN 23 amp UNUSED 18 UNUSED 22 19 2 5 x 20 21 BLOWER COIL 22 32 ow 23 24 46 26 nn 27 22 Q 28 5 lt 240 60 1 29 30 Start Kit is optional accessory START RELAY 31 OUTDOOR UNIT START CAP i 2 33 34 25 35 Crank Case Heater is optional accessory 36 208 230 60 1 Typical Wiring Schematic RSD A2 with BBA A2A blower 35 SCHEMATICS 36 SHORT CYCLE PROTECTOR OPTIONAL OR SCP FIELD INSTALLED HARD START KIT OPTIONAL OR FIELD INSTALLED YL SEE NOTE 5 BK1 COMPRESSOR NOTE 4 WARNING WIRING TO UNIT MUST BE PROPERLY POLARIZED AS APPLICABLE AND GROUNDED DISCONNECT FIELD CONNECTIONS POWER BEFORE SERVICING 1 PH POWER SEE NOTES 18
4. x SCHEDULED MAINTENANCE The owner should be made aware of the fact that as with any mechanical equipment the remote air conditioner re quires regularly scheduled maintenance to preserve high performance standards prolong the service life of the equip ment and lessen the chances of costly failure In many instances the owner may be able to perform some of the maintenance however the advantage of a service contract which places all maintenance in the hands of a trained serviceman should be pointed out to the owner 4 WARNING DISCONNECT POWER SUPPLY BEFORE SERVICING ONCE A MONTH 1 Inspect the return filters of the evaporator unit and clean or change if necessary NOTE Depending on opera tion conditions it may be necessary to clean the filters more often If permanent type filters are used they should be washed with warm water dried and sprayed with an adhesive according to manufacturers recommen dations 2 When operating on the cooling cycle inspect the con densate line piping from the evaporator coil Make sure the piping is clear for proper condensate flow SERVICING TEST EQUIPMENT Proper test equipment for accurate diagnosis is as essen tial as regular hand tools The following is a must for every service technician and ser vice shop 1 Thermocouple type temperature meter measure dry bulb temperature 2 Sling psychrometer measure relative humidity and wet bulb temperature 3 Am
5. Broken Internal Parts Replace Compressor Broken Values Inefficient Compressor Test Compressor Efficiency High Pressure Control Open Reset And Test Control Wrong Type Expansion Valve Expansion Valve Restricted Replace Valve Oversized Expansion Valve Undersized Expansion Valve Expansion Valve Bulb Loose Inoperative Expansion Valve Loose Hold down Bolts 10 SERVICING 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 9 5 12 5 13 5 15 S 15B S 16A S 16B 5 16 5 17 5 18 5 40 5 41 5 60 5 61 S 61B 5 62 5 100 5 101 5 102 5 103 5 104 5 105 5 106 5 107 5 108 5 109 5 110 5 113 5 114 5 115 5 116 5 116 Table of Contents CHECKING VOLTAGE ss 12 CHECKING WIRING aeae 12 CHECKING THERMOSTAT WIRING AND 12 CHECKING TRANSFORMER AND CONTROL CIRCUIT 13 CHECKING CYCLE PROTEC TOR sacssocezsivesdsesiecastnces araea ea e ar ieia naaar A AN aaraa 13 CHECKING TIME DELAY RELAY 2 ta 13 CHECKING CONTACTOR AND OR RELAYS ien bie ea i et eae 14 CHECKING FAN RELAY CONTACTS 14 CHECKING HIGH PRESSURE CONTROL 15 CHECKING LOW PRESSUR
6. Faulty Thermostat Faulty Transformer Shorted or Open Capacitor Internal Overload Open Test Continuity of Overload Shorted or Grounded Compressor Test Motor Windings Compressor Stuck Use Test Cord Faulty Compressor Contactor Faulty Fan Relay Test continuity of Coil amp Contacts Test continuity of Coil And Contacts Open Control Circuit Test Control Circuit with Voltmeter Test Voltage Shorted or Grounded Fan Motor Repair or Replace Test Motor Windings Improper Cooling Anticipator Check resistance of Anticipator Shortage of Refrigerant Test For Leaks Add Refrigerant Restricted Liquid Line Undersized Liquid Line Replace Restricted Part Replace Line Undersized Suction Line Replace Line Dirty Air Filter Inspect Filter Clean or Replace Dirty Indoor Coil Not enough air across Indoor Coil Inspect Coil Clean Speed Blower Check Dust Static Pressure Too much air across Indoor Coil Reduce Blower Speed Overcharge of Refrigerant Recover Part of Charge Dirty Outdoor Coil Noncondensibles Inspect Coil Clean Remove Charge Evacuate Recharge Recirculation of Condensing Air Remove Obstruction to Air Flow Infiltration of Outdoor Air Check Windows Doors Vent Fans Etc Located Thermostat Air Flow Unbalanced Relocate Thermostat Readjust Air Volume Dampers System Undersized Refigure Cooling Load
7. 4 WARNING Disconnect Electrical Power Supply a4 Disassemble and remove the heating element 2 Visually inspect the heater assembly for any breaks in the wire or broken insulators 3 Using an ohmmeter test the element for continuity no reading indicates the element is open Replace as necessary S 100 REFRIGERATION REPAIR PRACTICE 4 DANGER ALWAYS REMOVE THE REFRIGERANT CHARGE IN A PROPER MANNER BEFORE APPLYING HEAT TO THE SYSTEM When repairing the refrigeration system 4 WARNING Disconnect Electrical Power Supply 1 Never open a system that is under vacuum Air and moisture will be drawn in SERVICING 2 Plug or cap all openings 3 Remove all burrs and clean the brazing surfaces of the tubing with sand cloth or paper Brazing materials do not flow well on oxidized or oily surfaces 4 Cleanthe inside of all new tubing to remove oils and pipe chips 5 When brazing sweep the tubing with dry nitrogen to prevent the formation of oxides on the inside surfaces 6 Complete any repair by replacing the liquid line drier in the system evacuate and charge BRAZING MATERIALS Copper to Copper Joints Sil Fos used without flux alloy of 15 silver 80 copper and 5 phosphorous Recom mended heat 1400 F Copper to Steel Joints Silver Solder used without a flux alloy of 30 silver 38 copper 32 zinc Recommended heat 1200 F S 101 LEAK TESTING Refrigerant leaks are best dete
8. RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS 4 amp DANGER DANGER Immediate hazards which WILL result in severe personal injury or death WARNING Hazards or unsafe practices which COULD a WARNING result in severe personal injury or death CAUTION Hazards or unsafe practices which COULD a CAUTION result in minor personal injury or product or property damage 2 IMPORTANT INFORMATION IF REPAIRS ARE ATTEMPTED BY UNQUALIFIED PERSONS DANGEROUS A WARNING CONDITIONS SUCH AS EXPOSURE TO ELECTRICAL SHOCK MAY RESULT THIS MAY CAUSE SERIOUS INJURY OR DEATH AMANA WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAM A CAUTION AGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES IF YOU PERFORM SERVICE ON YOUR OWN PRODUCT YOU ASSUME RESPON SIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT To locate an authorized servicer please consult your telephone book or the dealer from whom you purchased this product For further assistance please contact CONSUMER INFORMATION LINE AMANA TOLL FREE 1 877 254 4729 U S only email us at hac consumer affairs amanahvac com fax us at 931 438 4362 Not a technical assistance line for dealers Outside the U S call 1 931 433 6101 Not a technical assistance line for dealers Your telephone company will bill you for the call SYSTEM CONTAMINANTS IMPROPER SERVICE PROCEDURE AND OR PHYSI A WARNING CAL ABUSE AFFECTING HERMETIC COMPRESSOR ELECTRICAL
9. measure static pressure and pres sure drop across coils Other recording type instruments can be essential in solv ing abnormal problems however in many instances they may be rented from local sources Proper equipment promotes faster more efficient service and accurate repairs with less call backs COOLING amp HEATING PERFORMANCE TEST Before attempting to diagnose an operating fault run a Cooling and or Heating Performance Test and apply the results to the Service Problem Analysis Guide SCHEDULED MAINTENANCE Complaint POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE POSSIBLE CAUSE SYMPTOM System will not start Power Failure No Cooling Compressor and Condenser Fan will not start Evaporator fan will not start Compressor runs goes off on overload Compressor will not start fan runs Compressor cycles on overload Condenser fan will not start Unsatisfactory Cooling System runs continuously little cooling Too cool and then too warm Not cool enough on warm days Certain areas too cool others too warm Compressor is noisy System Operating Pressures Low suction pressure Low head pressure High suction pressure High head pressure Test Method Remedy Test Voltage See Service Procedure Reference Blown Fuse Impact Fuse Size amp Type Loose Connection Inspect Connection Tighten Shorted or Broken Wires Open Overload Test Circuits With Ohmmeter
10. refrigerant hose to the liquid line dill valve and properly remove and dispose of the refrigerant Now determine if a burn out has actually occurred Confirm by analyzing an oil sample using a Sporlan Acid Test Kit AK 3 or its equivalent Remove the compressor and obtain an oil sample from the suction stub If the oil is not acidic either a burnout has occurred or the burnout is so mild that a complete clean up is not necessary If acid level is unacceptable the system must be cleaned by using the clean up drier method 4 CAUTION DO NOT ALLOW THE SLUDGE OR OIL TO CONTACT THE SKIN SEVERE BURNS MAY RESULT NOTE The Flushing Method using R 11 refrigerant is no longer approved by Amana Heating Cooling Suction Line Drier Clean Up Method The POE oils used with R410A refrigerant is an excellent solvent In the case of a burnout the POE oils will remove any burnout residue left in the system If not captured by the refrigerant filter they will collect in the compressor or other system components causing a failure of the replacement compressor and or spread contaminants throughout the system damaging additional components Use AMANA part number RF000127 suction line filter drier kit This drier should be installed as close to the compressor suction fitting as possible The filter must be accessible and be rechecked for a pressure drop after the system has operated for a time It may be necessary to use new tubing and for
11. sent to the control board at the time The variable speed motor is controlled via a PWM Pulse Width Modulated signal from the control board Nominal CFM is at an 80 PWM output ce TONAGE ABC ADJUST TABLE 1 TABLE 2 TABLE 2 TABLE 1 LED STATUS INDICATOR BBC Interface Board 11106901 5 60 ELECTRIC HEATER OPTIONAL ITEM Optional electric heaters may be added in the quantities shown in the specifications section to provide electric resis tance heating Under no condition shall more heaters than the quantity shown be installed The low voltage circuit in the air handler is factory wired and terminates at the location provided for the electric heater s A minimum of field wiring is required to complete the installation Other components such as a Heating Cooling Thermostat and Outdoor Thermostats are available to complete the installation The system CFM can be determined by measuring the static pressure external to the unit The installation manual supplied with the blower coil or the blower performance table in the service manual shows the CFM for the static measured Alternately the system CFM can be determined by operat ing the electric heaters and indoor blower WITHOUT having the compressor in operation Measure the temperature rise as close to the blower inlet and outlet
12. the control will decrease the blower CFM by 10 and wait 30 seconds to see if the minimum supply air temperature is met If the minimum supply air temperature is not met the control will return the blower CFM to the preset CFM turn on one bank of electric heat and wait another 30 seconds to see if the supply air is at or above the minimum supply air setting The control will repeat this procedure until the supply air is at or above minimum supply air setting The control will then maintain all existing banks of electric heaters and CFM settings until the thermostat has been satisfied If the supply air temperature is above the upper limit of the acceptable range 150 F the control turns off one bank of heaters every 10 seconds until the temperature falls below 150 F Should the temperature exceed 160 F the control logic will shut off all electric heat and runs the fan continu ously until the temperature is back below 105 F BBC Manual Fan Operation The control board has a special option for the BBC models When the thermostat is switched to the FAN ON position the blower motor will operate at either 50 or 100 of the cooling speed This is accomplished with the use of the Low Speed Manual Fan jumper located just below the indicator light on the control board With the jumper in place as shipped the blower will operate at 50 of the nominal cooling speed selected With the jumper removed the blower will operate at 100 of
13. 29 inches gauge before opening valve to thermocouple vacuum gauge 23 Continue to evacuate to a maximum of 250 microns Close valve to vacuum pump and watch rate of rise If vacuum does not rise above 1500 microns in three to five minutes system can be considered properly evacuated 6 If thermocouple vacuum gauge continues to rise and levels off at about 5000 microns moisture and non condensables are still prevent If gauge continues to rise leak is present Repair and re evacuate 7 Closevalve to thermocouple vacuum gauge and vacuum pump Shut off pump and prepare to charge S 103 CHARGING Charge the system with the exact amount of refrigerant Refer to the specification section or check the unit name plates for the correct refrigerant charge An inaccurately charged system will cause future prob lems 1 When using an ambient compensated calibrated charg ing cylinder allow liquid refrigerant only to enter the high side 2 After the system will take all it will take close the valve on the high side of the charging manifold 3 Start the system and charge the balance of the refriger ant through the low side NOTE R410A should be drawn out of the storage container or drum in liquid form due to its fractionation properties but should be Flashed to it s gas state before entering the system There are commercially available restriction de vices thatfit into the system charging hose set to accomplish
14. 5 0 6 0 7 0 8 1 0 Fitting Size 1 0 Inches EXAMPLE One 7 8 90 short radius copper sweat ell is equal to the resistance of two foot of 7 8 O D straight pipe To obtain the total equivalent length add length of straight pipe to equivalent length of fittings NOTE The outdoor unit s refrigerant holding charge is for the matched indoor coil plus 25 feet of liquid line Ifthe piping run is longer than 25 feet additional refrigerant may be needed depending on the indoor coil that is used The following charge correction chart REFRIGERANT LINES IN EXCESS OF 50 FEET It is always best to keep refrigerant lines to 30 feet or less however this is not always possible The following informa tion should be used to size refrigerant lines in excess of 50 feet 1 Sketch the system and determine the number of traps required Traps are required only if the condensing unit is above the evaporator coil Traps are only necessary in the suction line Oil Trap guide lines Gas velocity 500 to 1999 Ft Min oil trap every 10 ft Gas velocity 2000 to 2999 Ft Min oil trap every 20 ft Gas velocity 3000 Ft Min or greater oil trap every 30 ft R410A Refrigerant Flow Rates R410A Refrigerant Flow Rates Ft Min Ft Min Ft Min Ft Min 5 8 Tube 3 4 Tube 7 8 Tube 1 1 8 Tube 024 ____1 470 2 The first trap goes the outlet of the evaporator coil The remaining traps go halfway up the riser 2 traps t
15. Heat is continually being transferred to the cool fins and tubes of the indoor evaporator coil by the warm system air This warming process causes the refrigerant to boil The heat removed from the air is carried off by the vapor As the vapor passes through the last tubes of the coil it becomes superheated that is itabsorbs more heat than is necessary to vaporize it This is assurance that only dry gas will reach the compressor Liquid reaching the compressor can weaken or break compressor valves The compressor increases the pressure of the gas thus adding more heat and discharges hot high pressure super heated gas into the outdoor condenser coil In the condenser coil the hot refrigerant gas being warmer than the outdoor air first loses its superheat by heat trans ferred from the gas through the tubes and fins of the coil The refrigerant now becomes saturated part liquid part vapor and then continues to give up heat until it condenses to a liquid alone Once the vapor is fully liquefied it continues to give up heat which subcools the liquid and it is ready to repeat the cycle SYSTEM OPERATION BBA Standard Efficiency Blower Section Sequence of Operation BBA Cooling Only Operations The cooling operation is fairly straight forward With the ther mostat in the FAN AUTO position and a Y or call the blower starts within three seconds When the Y call is satisfied the blower will stay on until th
16. SU FUSE FAN i om FAN cm LED lt lt 12 STATUS gt INDICATOR 5 ERYR 6 com gt scm u fF 9 2 elle somme Je LL BBA Control Board 11074205 The BBA control board contains a relay that is operated based on inputs from the room thermostat and thermistor The relay and therefore the blower is controlled per the following table Control Board Action Y off Relay de energized after supply air rises while O has above 65 F or 45 seconds whichever is been on shorter y off Relay de energizes after supply air falls below 85 F or 45 seconds whichever is shorter Relay energized until thermistor operation is restored Blower runs continuously Supply Air Relay energized until supply air is gt 170 below 85 F We Relay energized instantly vou Relay de energized instantly Thermistor Error off The BBC control board works in conjunction with the BBC interface board to control the blower motor and heaters based on inputs from the room thermostat and thermistor 20 P4
17. Thermistor mistor Temp Res Q Te 90 29610 130 Thermistor Res Q F 0 79600 5 5 Temp 5 6 7 41800 23100 36660 20470 85 33640 14970 Thermistor Resistance Table Also included on the BBC model control boards is a two pin header that allows for either 50 or 100 of nominal airflow during fan only mode The boardis shipped with the connec tion for 50 airflow during fan only mode 5 41 BBC INTERFACE BOARD OPERATION The BBC A2A model blowers have an interface board in corporated into the control circuitry This board serves as a selector for the various tonnage selections available see unit wiring diagram The unit wiring diagram indicates the appropriate pin positioning for each available tonnage se lection The board also contains an adjust tap which al lows for a 15 variation in airflow This feature allows for an increase decrease of the airflow over the entire operat ing range See the tables in the Airflow section for the avail able airflow ranges There is a LED included on the interface board the BBC models in addition to the one found onthe maincontrol The LED serves to indicate the airflow that the motor is deliver ing depending upon the positioning of the pin selectors on the interface board The number of blinks multiplied by 100 yields the programmed CFM The indicated CFM may vary depending on the mode of operation and the signals being
18. VAC at terminals and Remove 24 VAC at terminals R and R Should read 0 VAC at and Reapply 24 VAC to R1 and R2 within approximately three 3 to four 4 minutes should read 24 VAC at Y and If not as above replace relay aR woh S 6 CHECKING TIME DELAY RELAY Time delay relays are used in some of the blower cabinets to improve efficiency by delaying the blower off time Time delays are also used in electric heaters to sequence in multiple electric heaters 4 WARNING Disconnect Electrical Power Supply 1 Tag and disconnect all wires from male spade connec tions of relay 2 Using an ohmmeter measure the resistance across terminals H1 and H2 Should read approximately 150 ohms 3 Using an ohmmeter check for continuity across termi nals 3 and 1 and 4 and 5 13 SERVICING 4 Apply 24 volts to terminals H1 and H2 Check for continuity across other terminals should test continu ous If not as above replace NOTE The time delay for the contacts to make will be approximately 20 to 50 seconds and to open after the coil is de energized is approximately 40 to 90 seconds OHMMETER TESTING COIL CIRCUIT S 7 CHECKING CONTACTOR AND OR RELAYS The compressor contactor and other relay holding coils are wired into the low or line voltage circuits When the control circuit is energized the coil pulls in the normally open contacts or opens the normally closed contacts When the coil
19. an overcharged unit by referring to the cooling performance charts in the servicing section 2 Check the operation of the power elementin the valve as explained in S 26 Checking Expansion Valve Operation 3 Check for restricted or plugged equalizer tube S 107 UNDERFEEDING Underfeeding by the expansion valve results in low system capacity and low suction pressures If these symptoms are observed 1 Check for a restricted liquid line or drier A restriction will be indicated by a temperature drop across the drier 2 Check the operation ofthe power elementof the valve as described in S 26 Checking Expansion Valve Opera tion S 108 SUPERHEAT The expansion valves are factory adjusted to maintain 8 to 12 degrees superheat of the suction gas Before checking the superheat or replacing the valve perform all the proce dures outlined under Air Flow Refrigerant Charge Expan sion Valve Overfeeding Underfeeding These are the most common causes for evaporator malfunction CHECKING SUPERHEAT Refrigerant gas is considered superheated when its tem perature is higher than the saturation temperature corre sponding to its pressure The degree of superheat equals the degrees of temperature increase above the saturation temperature at existing pressure See Temperature Pres sure Chart next collum 1 Attach accurate thermometer or preferably thermo couple type temperature tester to the suction line near the sucti
20. as needed gt With ample voltage line voltage connectors energize the unit Measure the voltage with the unit starting and operating and determine the unit Locked Rotor Voltage NOTE If checking heaters be sure all heating elements are energized Locked Rotor Voltage is the actual voltage available at the compressor during starting locked rotor or a stalled condition Measured voltage should be above minimum listed in chart below To measure Locked Rotor Voltage attach a voltmeter to the and common terminals of the compres sor or to the T and T terminals of the contactor Start the unit and allow the compressor to run for several seconds then shut down the unit Immediately attempt to restart the unit while measuring the Locked Rotor Voltage 6 Lock rotor voltage should read within the voltage tabula tion as shown If the voltage falls below the minimum voltage check the line wire size Long runs of under sized wire can cause low voltage If wire size is ad equate notify the local power company in regard to either low or high voltage REMOTE CONDENSING UNITS BLOWER COILS 115 MAX 127 NOTE When operating electric heaters on voltages other than 240 volts refer to the System Operation section on electric heaters to calculate temperature rise and air flow Low voltage may cause insufficient heating 12 S 2 CHECKING WIRING 4 WARNING Disconnect Elect
21. bearing surfaces causing premature bearing failure S 104 CHECKING COMPRESSOR EFFICIENCY The reason for compressor inefficiency is broken or dam aged scroll flanks on Scroll compressors reducing the ability of the compressor to pump refrigerant vapor The condition of the scroll flanks is checked in the following manner 1 Attach gauges to the high and low side of the system 2 Start the system and run a Cooling Performance Test If the test shows a Below normal high side pressure b Above normal low side pressure c Low temperature difference across coil d Low amp draw at compressor Andthe charge is correct The compressor is faulty replace the compressor S 105 THERMOSTATIC EXPANSION VALVE The expansion valve is designed to control the rate of liquid refrigerant flow into an evaporator coil in exact proportion to the rate of evaporation of the refrigerant in the coil The amount of refrigerant entering the coil is regulated since the valve responds to temperature of the refrigerant gas leaving the coil feeler bulb contact and the pressure of the refrig erant in the coil This regulation of the flow prevents the return of liquid refrigerant to the compressor The illustration below shows typical heatpump TXV check valve operation in the heating and cooling modes Try COOLING HEATING TXV VALVES Some TXV valves contain an internal check valve thus eliminating the
22. bulb in your hand As you warm the bulb the suction pressure should rise and the suction tem perature will fall 4 temperature or pressure change is noticed the expansion valve is operating If no change is noticed the valve is restricted the power element is faulty or the equalizer tube is plugged 5 Capture the charge replace the valve and drier evacu ate and recharge 27 SERVICING S 113 CHECKING RESTRICTED LIQUID LINE When the system is operating the liquid line is warm to the touch If the liquid line is restricted a definite temperature drop will be noticed at the point of restriction In severe cases frost will form at the restriction and extend down the line in the direction of the flow Discharge and suction pressures will be low giving the appearance of an undercharged unit However the unit will have normal to high subcooling Located the restriction replace the restricted part replace drier evacuate and recharge S 114 OVERCHARGE OF REFRIGERANT An overcharge of refrigerant is normally indicated by an excessively high head pressure An evaporator coil using an expansion valve metering device will basically modulate and control a flooded evapo rator and prevent liquid return to the compressor An evaporator coil using a capillary tube metering device could allow refrigerant to return to the compressor under extreme overcharge conditions Also with a capillary tube metering device extre
23. control board has malfunctioned and must be replaced If the LED indicates 4 flashes thermistor error then the resistance should be checked between the terminations of the thermistor leads at the control board making sure that the terminals are securely attached insuring a good connec tion Failures such as opens shorts across the device shorts to ground shorts to power and leakage path to ground shall be sensed The thermistor or wire s should be replaced for proper operation SERVICING If the LED indicates 6 flashes system error then the setup and configuration of the system should be checked This error mode could indicate an abnormal operating condition such as a restricted inlet blocked outlet or possibly a leak in the unit or ductwork The system should be checked for such a condition If the LED is in a continuous on mode control board malfunction then all field and factory connections should be checked If the error mode still occurs after a power reset then the control board should be replaced NOTE After an error mode occurs the system requires a power reset for normal operation after the problem has been corrected The control board is programmed with a certain range of acceptable values from the thermistor depending on the mode of operation The control board knows the mode of operation based on the thermostat inputs and thus knows the acceptable range of resistance readings from the ther
24. is de energized springs return the contacts to their normal position NOTE Most single phase contactors break only one side of the line L1 leaving 115 volts to ground present at most internal components 4 WARNING Disconnect Electrical Power Supply 1 Remove the leads from the holding coil 2 Using an ohmmeter test across the coil terminals If the coil does not test continuous replace the relay or contactor S 8 CHECKING CONTACTOR CONTACTS 4 WARNING Disconnect Electrical Power Supply 1 Disconnect the wire leads from the terminal T side of the contactor 2 With power ON energize the contactor 4 WARNING LINE VOLTAGE NOW PRESENT 3 Using a voltmeter test across terminals 12 T1 No voltage indicates CC1 contacts open If ano voltage reading is obtained replace the contactor VOLT OHM METER Ohmmeter for testing holding coil Voltmeter for testing contacts TESTING COMPRESSOR CONTACTOR S 9 CHECKING FAN RELAY CONTACTS 4 WARNING Disconnect Electrical Power Supply 1 Disconnect wires leads from terminals 2 and 4 of Fan Relay Cooling and 2 and 4 5 and 6 of Fan Relay Heating 2 Using anohmmeter test between 2 and 4 should read open Test between 5 and 6 should read continuous 3 With power ON energize the relays 4 WARNING LINE VOLTAGE NOW PRESENT OHMMETER TESTING FAN RELAY 4 Using anohmmeter test between 2 and 4 should read continuous Te
25. need for an external check valve and bypass loop The three forces which govern the operation of the valve are 1 the pressure created in the power assembly by the feeler bulb 2 evaporator pressure and 3 the equivalent pressure of the superheat spring in the valve 0 bleed type expansion valves are used on indoor and outdoor coils The 0 bleed valve will not allow the system pressures High and Low side to equalize during the shut down period The valve will shut off completely at approxi mately 100 PSIG SERVICING 30 bleed valves used on some other models will continue to allow some equalization even though the valve has shut off completely because of the bleed holes within the valve This type of valve should not be used as a replacement for a0 bleed valve due to the resulting drop in performance The bulb must be securely fastened with two straps to a clean straight section of the suction line Application of the bulb to a horizontal run of line is preferred If a vertical installation cannot be avoided the bulb must be mounted so that the capillary tubing comes out at the top THE VALVES PROVIDED BY AMANA ARE DESIGNED TO MEET THE SPECIFICATION REQUIREMENTS FOR OPTIMUM PRODUCT OPERATION DO NOT USE SUB STITUTES S 106 OVERFEEDING Overfeeding by the expansion valve results in high suction pressure cold suction line and possible liquid slugging of the compressor If these symptoms are observed 1 Check for
26. the open neutral 9 Setthe thermostat to Using avoltmeter check for 24 volts between pin 15 G and common 10 Disconnect power to compressor Set thermostat to call for cooling Using a voltmeter check for 24 volts at pin 6 and or 14 11 Set the thermostat to a call for heating Using a voltme ter check for 24 volts at pin 2 and or 11 OUT 8 Ce OUT ADJUST 7 15 14 2 COOL 5 13 EM 2 DELAY _ 4 12 24 Vac R HEAT ww 2 BK PWM SPEED COMMON1 1 9 REV VALVE 16 PIN ECM HARNESS CONNECTOR If you do not read voltage and continuity as described the problem is in the control or interface board but not the motor If you register voltage as described the ECM power head is defective and must be replaced S 16C CHECKING ECM MOTOR WINDINGS 4 WARNING Disconnect Electrical Power Supply 1 Disconnectthe 5 pin and the 16 pin connectors from the ECM power head 2 Remove the 2 screws securing the ECM power head and separate it from the motor 3 Disconnect the 3 pin motor connector from the power head and lay it aside 4 Using an ohmmeter check the motor windings for con tinuity to ground pins to motor shell If the ohmmeter indicates continuity to ground the motor is defective and must be replaced 5 Using an ohmmeter check the windings
27. the refrigerant correction factor and subtract the factory charge for the line set 65 x 0 55 35 75 25 x 0 55 13 75 22 oz additional charge p i y L To determine the subcooling value for this application refer to spec sheet or technical information manual The design subcooling for RSD48 is 10 5 F Add the subcooling loss for the liquid line length 5 4 F less 2 F equals 13 9 F subcooling at the liquid line service valve 31 SERVICING REFRIGERANT LINE SIZING Known Factors 1 2 3 RSD36A2A and matching A coil Condenser above Evaporator Liquid Line 72 linear feet w 6 long radius elbows Suction Line 72 linear feet and 43 ft vertical lift Determine Suction and Liquid Line sizes Procedures A B Measure length of suction line 72 ft Measure the vertical lift of the suction line 43 Using the Suction Line Traps Chart determine the number of traps required in the suction line 3 Count the number of suction line elbows 6 long radius Calculate the equivalent length of fittings using the appropriate charts Calculate using the recommended suction line size for each unit 6x 1 7 10 2 Traps X 4 6 13 8 10 2 13 8 24 equivalent feet Add suction line length A and equivalent feet of fittings 72 24 96 effective feet The total equivalent length of Suction Line is 96 feet Refer to the Suction Line Sizing Chart to d
28. this DO NOT charge liquid R410A into the compressor 4 With the system still running close the valve on the charging cylinder At this time you may still have some liquid refrigerant in the charging cylinder hose and will definitely have liquid the liquid hose Reseatthe liquid line core Slowly open the high side manifold valve and transfer the liquid refrigerant from the liquid line hose and charging cylinder hose into the suction service valve port CAREFUL Watch so that liquid refrigerant does not enter the compressor 5 With the system still running back seat the valves remove hose and reinstall both valve caps 6 Check system for leaks Do not charge a remote condensing unit with non match ing evaporator coil or a system where the charge quantity is unknown Do not install or charge R410A condensers matched with coils having capillary tubes or flow control restrictors ARI rated Coil combinations with thermostatic expansion valves TEV s should be charged by subcooling See Checking Subcooling and Superheat sections in this manual Subcooling values for Ultron system are found in the Technical Information manuals for Ultron outdoor units Due to their design Scroll compressors are inherently more tolerant of liquid refrigerant 24 NOTE Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant continued floodback or flooded start conditions may wash oil from the
29. to thoroughly evacuate the system is a high vacuum pump capable of producing a vacuum equivalent to 25 microns absolute and a thermocouple vacuum gauge to give a true reading of the vacuum in the system NOTE Never use the system compressor as a vacuum pump or run when under a high vacuum Motor damage could occur 4 WARNING DO NOT FRONT SEAT THE SERVICE VALVE S WITH THE COMPRESSOR OPERATING IN AN ATTEMPT TO SAVE REFRIGERANT WITH THE SUCTION LINE OF THE COMPRESSOR CLOSED OR SEVERELY RE STRICTED 1 Connect the vacuum pump vacuum tight manifold set with high vacuum hoses thermocouple vacuum gauge and charging cylinder as shown 2 Startthe vacuum pump and open the shut off valve to the high vacuum gauge manifold only After the compound gauge low side has dropped to approximately 29 inches of vacuum open the valve to the vacuum thermo couple gauge See that the vacuum pump will blank off to maximum of 25 microns A high vacuum pump only produce a good vacuum if its oil is non contami nated THERMOCOUPLE VACUUM GAUGE DIAL A CHARGE To CHARGING CYLINDER RELATED GAUGE PORTS OF HIGH VACUUM PUMP EVACUATION 3 Ifthe vacuum pump is working properly close the valve to the vacuum thermocouple gauge and open the high and low side valves to the high vacuum manifold set With the valve on the charging cylinder closed open the manifold valve to the cylinder 4 Evacuate the system to at least
30. 222 68 229 70 236 72 274 82 283 84 291 86 299 88 308 90 317 92 326 94 335 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 68 66 64 62 70 68 66 64 243 74 72 70 68 66 64 251 76 74 72 70 68 66 259 78 76 74 72 70 68 266 80 78 76 74 72 70 80 78 76 74 82 80 78 76 EXAMPLE a Liquid Line Pressure 417 b Corresponding Temp F 120 c Thermometer on Liquid line 109 F To obtain the amount of subcooling subtract 109 F from 120 The difference is 11 subcooling See the specification sheet or technical information manual for the design subcooling range for your unit S 110 CHECKING EXPANSION VALVE OPERA TION 1 Remove the remote bulb of the expansion valve from the suction line 54 52 50 48 56 54 52 50 58 56 54 52 60 58 56 54 62 60 58 56 64 62 60 58 60 62 72 74 84 82 80 78 76 86 84 82 80 78 88 86 84 82 80 90 88 86 84 82 92 90 88 86 84 94 92 90 88 86 96 94 92 90 88 98 96 94 92 90 100 98 96 94 92 102 100 98 96 94 104 102 100 98 96 106 104 102 100 98 108 106 104 102 100 110 108 106 104 102 112 110 108 106 104 114 112 110 108 106 116 114 112 110 108 118 116 114 112 110 120 118 116 114 112 122 120 118 116 114 124 122 120 118 116 126 124 122 120 118 2 Start the system and cool the bulb in a container of ice water closing the valve As you cool the bulb the suction pressure should fall and the suction temperature will rise Next warm the
31. 440 0 442 0 444 0 446 0 448 0 450 0 452 0 454 0 456 0 458 0 460 0 462 0 464 0 466 0 468 0 470 0 472 0 474 0 476 0 478 0 480 0 482 0 484 0 486 0 488 0 490 0 492 0 494 0 496 0 498 0 500 0 502 0 504 0 506 0 508 0 510 0 512 0 514 0 516 0 518 0 520 0 ji ji ji ji 120 121 121 121 122 122 122 123 123 123 124 124 124 125 125 126 126 126 127 127 127 128 128 128 129 129 129 130 130 130 131 131 131 132 132 132 132 133 133 133 134 134 134 135 135 135 136 136 136 137 137 3 N N PSIG F 522 0 137 524 0 137 526 0 138 528 0 ___ 138 530 0 138 532 0 139 534 0 139 536 0 139 538 0 140 540 0 140 544 0 141 548 0 141 552 0 142 1 556 0 142 560 0 143 564 0 143 568 0 144 5720 145 5760 145 580 0 146 584 0 146 588 0 147 592 0 ___ 147 596 0 148 600 0 149 604 0 149 608 0 150 612 0 150 616 0 151 620 0 151 624 0 152 628 0 152 632 0 153 636 0 153 640 0 154 644 0 155 648 0 155 652 0 156 1 656 0 156 660 0 157 664 0 157 668 0 158 6720158 676 0 159 680 0 159 684 0 160 688 0 160 692 0 161 696 0 161 8 y SERVICING REQUIRED LIQUID LINE TEMPERATURE LIQUID PRESSURE REQUIRED SUBCOOLING TEMPERATURE F Valve esi Se ae sa 189 58 195 60 202 62 208 64 215 66
32. 6 T 2 ACCESSORIES A WARNING OPTIONAL OR FIELD INSTALLED HARD START KIT WIRING TO UNIT MUST BE PROPERLY POLARIZED AS APPLICABLE AND GROUNDED DISCONNECT POWER BEFORE SERVICING NOTES 1 SEE ELECTRICAL INFORMATION ON UNIT NAMEPLATE FIELD CONNECTIONS FOR 1 UNITS ARE TO BE MADE AT CONTACTOR amp EQUIPMENT GROUND SCREW 2 FOR FIELD CONNECTIONS SEE INSTALLATION INSTRUCTIONS 3 TRANSFORMER N E C CLASS 2 24VAC OUTPUT 20VA MINIMUM CANADIAN REQUIREMENTS 4 NEUTRAL IF INPUT POWER DERIVED FROM 240 416 SOURCE 5 CONTROL CIRCUIT GROUND 6 120 240 VAC 3 WIRE NOTE READ THE FOLLOWING NOTES BEFORE OPERATING OR SERVICING THIS UNIT 1 AMANA APPROVED REPLACEMENT PARTS MUST BE USED WHEN SERVICING 2 TOTAL SYSTEM CHARGE IS MARKED ON CONDENSER NAMEPLATE WHICH INCLUDES INDOOR SECTION AND 25 FEET OF INTERCONNECTING LIQUID LINE IF DIFFERENT LIQUID LINE LENGTH IS USED ADJUST PER FOLLOWING CHART 250 LIQUID LINE 20 OZ PER FOOT 312 LIQUID LINE 36 OZ PER FOOT 375 LIQUID LINE 55 OZ PER FOOT 500 LIQUID LINE 1 07 OZ PER FOOT TOTAL CHARGE BLOCK MUST BE STAMPED BY THE DEALER WHO INSTALLS THE UNIT FOR MORE COMPLETE INSTRUCTIONS SEE INSTALLATION INSTRUCTIONS gt 5 22 10 lt gt 5 90 cw W oc gre x Om Or 40 OF we AO 2 28 or za oa FO FACTORY SUPPLIED WIRING LOW VOLTAGE HIGH VOLTAGE FI
33. 765 49150 65530 81915 98295 FORMULAS Heating Output KW x 3413 x Corr Factor Actual CFM CFM from table x Corr Factor BTUH KW x 3413 BTUH CFM x 1 08 x Temperature Rise AT CFM KW x 3413 1 08 x AT AT BTUH CFM x 1 08 S 61A CHECKING HEATER LIMIT CONTROL S Each individual heater element is protected with a limit control device connected in series with each element to prevent overheating of components in case of low airflow This limit control will open its circuit at approximately 150 F 22 4 WARNING Disconnect Electrical Power Supply 1 Remove the wiring from the control terminals 2 Using an ohmmeter test for continuity across the nor mally closed contacts No reading indicates the control is open replace if necessary IF FOUND OPEN REPLACE DO NOT WIRE AROUND S 61B CHECKING HEATER FUSE LINK OPTIONAL ELECTRIC HEATERS Each individual heater element is protected with a one time fuse link which is connected in series with the element The fuse link will open at approximately 333 4 WARNING Disconnect Electrical Power Supply Remove heater element assembly so as to expose fuse link Using anohmmeter test across the fuse link for continu ity no reading indicates the link is open Replace as necessary NOTE The link is designed to open at approximately 333 DO NOT WIRE AROUND determine reason for failure 5 62 CHECKING HEATER ELEMENTS
34. CIRCUIT A step down transformer 208 240 volt primary to 24 volt secondary is provided with each indoor unit This allows ample capacity for use with resistance heaters The out door sections do not contain a transformer 4 WARNING Disconnect Electrical Power Supply 1 Remove control panel cover or etc to gain access to transformer With power ON 4 WARNING LINE VOLTAGE NOW PRESENT 2 Using a voltmeter check voltage across secondary voltage side of transformer R to C 3 No voltage indicates faulty transformer bad wiring or bad splices 4 Check transformer primary voltage at incoming line voltage connections and or splices 5 If line voltage available at primary voltage side of trans former and wiring and splices good transformer is inoperative Replace S 5 CHECKING CYCLE PROTECTOR Some models feature a solid state delay on make after break time delay relay installed in the low voltage circuit This control is used to prevent short cycling of the compres sor under certain operating conditions The component is normally closed R to Y A power interruption will break circuit R to Y for approximately three minutes before resetting 4 WARNING Disconnect Electrical Power Supply 1 Remove wire from terminal 2 Wait for approximately four 4 minutes if machine was running With power ON 4 WARNING LINE VOLTAGE NOW PRESENT 1 Apply 24 VAC to terminals R and R Should read 24
35. E CONTRO eaei 15 CHECKING CAPACITOR ee I a tee 15 CAPACITANCE CHEGK a lithe 16 CHECKING FAN AND BLOWER MOTOR WINDINGS PSC 16 CHECKING FAN AND BLOWER MOTOR MOTORS tendinta 17 i 17 CHECKING COMPRESSOR WINDINGS 3 ci 18 TESTING GRANKCASEIHEAT ER 19 BBA BBC CONTROL BOARD 20 BBC INTERFACE BOARD 21 HEATER 2 21 CHECKING HEATER LIMIT a ee a Sed ee 22 CHECKING HEATER FUSE ate 22 ELEMENTS 2 2 22 REFRIGERATION REPAIR PRACTICE 22 LEAK TESTING E epee eh eas een ial ne 23 23 CHARGING icc 24 CHECK
36. ELD SUPPLIED WIRING LOW VOLTAGE HIGH VOLTAGE COLOR CODE amp LEGEND 1ST GROUP COLOR 2ND GROUP NUMBER OR ORANGE BK BLACK YL YELLOW BU BLUE VT VIOLET RD RED BR BROWN TN TAN GN GREEN GY GRAY PK PINK WN WIRE 20324801 REV 0
37. ING COMPRESSOR 24 THERMOSTATIG EXPANSION VALVE eile Red ek eee eee 24 OVERFEEDING 25 5 25 25 CHECKING SUBCOOL ING 25 CHECKING EXPANSION VALVE OPERATION isinin 27 CHECKING RESTIRIGTED LIQUID LINE 28 OVERCHARGE OF 28 28 COMPRESSOR BURNOUT 28 a EE 29 11 SERVICING S 1 CHECKING VOLTAGE 4 WARNING Disconnect Electrical Power Supply 1 Remove outer case control panel cover etc from unit being tested With power ON 4 WARNING LINE VOLTAGE NOW PRESENT 2 Using a voltmeter measure the voltage across termi nals L1 and L2 of the contactor for the condensing unit or at the field connections for the air handler or heaters w No reading indicates open wiring open fuse s no power or etc from unit to fused disconnect service Repair
38. METER TESTING COMPRESSOR WINDINGS If either winding does not test continuous replace the compressor NOTE If an open compressor is indicated allow ample time for the internal overload to reset before replacing compres sor S 17B Ground Test If fuse circuit breaker ground fault protective device etc has tripped this is a strong indication that an electrical problem exists and must be found and corrected The circuit protective device rating must be checked and its maximum rating should coincide with that marked on the equipment nameplate With the terminal protective cover in place it is acceptable to replace the fuse or reset the circuit breaker ONE TIME ONLY to see if it was just a nuisance opening If it opens again DO NOT continue to reset Disconnect all power to unit making sure that all power legs are open 1 DONOT remove protective terminal cover Disconnect the three leads going to the compressor terminals at the nearest point to the compressor 2 Identify the leads and using a Megger Hi Potential Ground Tester or other suitable instrument which puts out a voltage between 300 and 1500 volts check for a ground separately between each of the three leads and ground such as an unpainted tube on the compressor Do not use a low voltage output instrument such as a volt ohmmeter SERVICING COMPRESSOR GROUND TEST 3 If a ground is indicated then carefully remove the compressor terminal protect
39. Negative Pressure 2 Measure the static pressure of the supply duct Positive Pressure 3 Add the two readings together TOTAL EXTERNAL STATIC NOTE Both readings may be taken simultaneously and read directly on the manometer if so desired 4 Consult proper table for quantity of air If external static pressure is being measured on a furnace to determine airflow supply static must be taken between the A coil and the furnace TOTAL EXTERNAL STATIC 202 COIL STATIC PRESSURE DROP 1 Using a draft gauge inclined manometer connect the positive probe underneath the coil and the negative probe above the coil 2 Adirect reading can be taken of the static pressure drop across the coil 3 Consult proper table for quantity of air STATIC PRESSURE DROP If the total external static pressure and or static pressure drop exceeds the maximum or minimum allowable statics check for closed dampers dirty filters undersized or poorly laid out duct work 33 SCHEMATICS Oa FF WO D 34 Thermostat shown for reference only See the thermostat installation instructions for additional information Start Kit is optional accessory OUTDOOR UNIT
40. OMPRESSOR E 93 J 123456 Motor Shift Year Month Serial No TECUMSEH COMPRESSOR T G 22 93C 123456 Month Day Year Serial No BRISTOL COMPRESSOR 291 93 123456 Dayof Year Serial No Year S 18 TESTING CRANKCASE HEATER OPTIONAL ITEM The crankcase heater must be energized a minimum of four 4 hours before the condensing unit is operated Crankcase heaters are used to prevent migration or accu mulation of refrigerant in the compressor crankcase during the off cycles and prevents liquid slugging or oil pumping on start up A crankcase heater will not prevent compressor damage due to a floodback or over charge condition 4 WARNING Disconnect Electrical Power Supply 1 Disconnect the heater lead in wires 2 Using an ohmmeter check heater continuity should test continuous if not replace NOTE The positive temperature coefficient crankcase heater is a 40 watt 265 voltage heater The cool resistance of the heater will be approximately 1800 ohms The resis tance will become greater as the temperature of the com pressor shell increases 19 SERVICING S 40 BBA BBC CONTROL BOARD OPERATION UNUSED UNUSED TR T kl 3 b m F S m FAN IDLE e lt
41. Only Operations As in the cooling only operations with the thermostat in the FAN AUTO position W2 or call the first bank of electric heat is energized as the blower ramps up to speed 30 second period The control logic continues turning on banks of electric heat one every ten seconds until the supply temperature reaches set point of 110 F The board will then keep all existing banks of electric heaters on until the W2 or E call has been satisfied The minimum supply air setting has no effect in this mode If the W2 or E call has not been satisfied within the ten minutes the board increases the minimum supply temperature to 120 If the supply air temperature goes above the upper limit of the acceptable range 150 F the control turns off one bank of heaters every 10 seconds until the temperature falls below 150 F Should the temperature exceed 160 F the control logic will shut off all electric heat and runs the fan continu ously until the temperature is back below 105 F BBC Heat Pump With Back Up Electric Heat Operations With the thermostat in the FAN AUTO position and a W2 and signal after 30 seconds the control compares the supply air temperature to the minimum supply air setting on the control If the supply air is at or above the minimum supply air setting no electric heat is energized If the supply is below the minimum supply air setting
42. TERMINALS MAY CAUSE DANGEROUS SYSTEM VENTING System contaminants improper Service Procedure and or physical abuse affecting hermetic compressor electrical terminals may cause dangerous system venting The successful development of hermetically sealed refrigeration compressors has completely sealed the compressor s moving parts and electric motor inside a common housing minimizing refrigerant leaks and the hazards sometimes associated with moving belts pulleys or couplings Fundamental to the design of hermetic compressors is a method whereby electrical current is transmitted to the compressor motor through terminal conductors which pass through the compressor housing wall These terminals are sealed in a dielectric material which insulates them from the housing and maintains the pressure tight integrity of the hermetic compressor The terminals and their dielectric embedment are strongly constructed but are vulnerable to careless compressor installation or maintenance procedures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants In either of these instances an electrical short between the terminal and the compressor housing may result in the loss of integrity between the terminal and its dielectric embedment This loss may cause the terminals to be expelled thereby venting the vaporous and liquid contents of the compressor housing and system A venting compressor terminal normally presen
43. ack seating valves were factory installed to accept the field run copper The total refrigerant charge needed for a normal installation is also factory installed For additional refrigerant line set information refer to the Technical Information manual of the unit you are servicing Compressors Amana RSD outdoor units use Copeland Compliant ZP series scroll compressors There are a number of design characteristics which differentiate the scroll compressor from the reciprocating compressor One is the scroll A scroll is an involute spiral which when matched with a mating scroll form generates a series of crescent shaped gas pockets between the members see following illustra tion During compression one scroll remains stationary while the other form orbits This motion causes the resulting gas pocket to compress and push toward the center of the scrolls When the center is reached the gas is discharged out a port located at the compressor center COILS AND BLOWER COILS Amana CA CH and CF coils are designed to be installed with a furnace or air handler unit and matched with Amana RSD condensing units to provide high efficiency heating and cooling R410A rated thermal expansion valves are required on the CA_F CH_F and CF_F coils to give accurate refrigerant control and provide reliable operation over a wide range of conditions Amana CA coils are designed for upflow and counterflow operation The CH slab coils and the CF c
44. as possible If other than a 240V power supply is used refer to the BTUH CAPACITY CORRECTION FACTOR chart below BTUH CAPACITY CORRECTION FACTOR 84 75 MULTIPLICATION FACTOR 1 08 92 EXAMPLE Five 5 heaters provide 24 0 KW at the rated 240V Our actual measured voltage is 220V and our measured temperature rise is 42 F Find the actual CFM Answer 24 0KW 42 F Rise 240 V 1800 CFM from the TEMPERATURE RISE chart on the right Heating output at 220 V 24 0KW x 3 413 x 84 68 8 MBH Actual CFM 1800 x 84 Corr Factor 1400 CFM 21 SERVICING NOTE The temperature rise table is for sea level installa tions The temperature rise at a particular KW and CFM will be greater at high altitudes while the external static pres sure at a particular CFM will be less TEMPERATURE RISE 240V K KW KW KW KW KW 25 f 2 a3 a 5 19 s 8 5 2 19 17 14 13 12 1 29 9 E 6 m 3 ES 4 4455 13 19 25 38 50 2 23 35 46 it 16 22 32 4 54 to 15 20 4 5 47 ie 27 36 44 8e 3 1 25 s 42 2000 8 12 15 38 10 13 20 26 33 ELECTRIC HEATER CAPACITY BTUH HTR 4 8 7 2 9 6 14 4 19 2 24 0 28 8 16380 24915 32
45. ated for R410A Alternate Refrigerant installations Alternate Refrigerant R410A rated manifold gauge set Alternate Refrigerant R410A rated hose set These hoses have the 1 2 20TPI connections to fit the RSD service valves Alternate Refrigerant R410A adapter Will adapt from the Amana 1 2 20 TPI connection to 1 4 flare connection to allow use of R410A rated manifold gauge sets PRODUCT DESIGN This section gives basic description of cooling unit operation its various components and their basic operation Ensure your system is properly sized for heat gain and loss according to methods of the Air Conditioning Contractors Association ACCA or equivalent CONDENSING UNIT These units are designed for free air discharge Con densed air is pulled through the condenser coil by a direct drive propeller fan and then discharged from the cabinettop The unit requires no additional resistance i e duct work and should not be added The RSD condensing units are designed for 208 230 dual voltage single phase applications The units range in size from 2 to 5 ton and have a rating of 13 SEER The actual system efficiency is dependent upon the unit and its components Refer to the Technical Information manual of the unit you are servicing for further details Suction and Liquid Line Connections The suction and liquid line connections of the unit are set up for field piping with refrigerant type copper B
46. cted with an electronic leak detector rated for use with HFC refrigerants For a system that contains a refrigerant charge and is suspected of having a leak stop the operation and hold the exploring tube of the detector as close to the tube as possible check all piping and fittings Ifa leak is detected do not attempt to apply more brazing to the joint Remove and capture the charge unbraze the joint clean and re braze For a system that has been newly repaired and does not contain a charge connect a cylinder of refrigerant through a gauge manifold to the service ports NOTE Refrigerant hoses must be rated for use with R410A refrigerant and equipped with dill valve depressors Open the valve on the cylinder and manifold and allow the pres sure to build up within the system Test for leaks as described above After the test has been completed remove and capture the leak test refrigerant S 102 EVACUATION This is the most important part of the entire service proce dure The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air non condensables and moisture from the system Air in a system causes high condensing temperature and pressure resulting in increased power input and reduced performance Moisture chemically reacts with the refrigerant oil to form corrosive acids These acids attack motor windings and parts causing breakdown The equipment required
47. e supply tempera ture is greater than 65 F or up to a maximum of forty five seconds whichever occurs first BBA Electric Heat Only Operations As in the cooling only operations with the thermostat in the FAN AUTO position and a W2 or call the blower starts within three seconds The board then starts turning on banks of electric heat one every ten seconds until the supply temperature reaches 90 F If the W2 or E call has not been satisfied within the next five minutes the board turns on additional banks of heaters and increases the minimum supply temperature selectable from 90 F to 110 F If an additional five minutes passes and the W2 or E call has not been satisfied the board will raise the minimum supply temperature to 120 F and once again turns on additional banks of electric heaters Should the temperature at the thermistor go above 150 F the control logic will start turning off one bank of heaters every ten seconds until the temperature falls below 150 F If the temperature climbs above 160 F the control logic turns off all electric heat and keeps the blower on until the temperature falls below 85 F BBA Fan Idle Option The control board has a special option for the BBA models The blower motor is wired for only one speed for heating and cooling operations The control has a Fan Idle tap that is energized when there is not a call for heating cooling or fan operation A
48. etermine the actual suction line required Since 96 is greater than 75 but less than 100 use the 100 column 3 4 Suction line will be adequate with a 3 6 capacity loss Measure liquid line length 72 ft G Count the number of liquid line elbows 6 long radius Calculate the equivalent length of fittings using the Fitting Losses in Equivalent Feet Chart Calculate using the recommended liquid line size for each unit 8 4 8 equivalent feet Add liquid line length equivalent feet of fittings 72 4 8 76 8 effective feet The total effective length of liquid line is 76 8 ft Refer to the Liquid Line Sizing Chart to determine the liquid line subcooling loss 76 8 effective feet of 5 16 tubing will have 4 4 F subcooling loss less the subcooling gain due to the vertical drop 43 ft 4 3 F for a net 0 1 F subcooling loss 5 16 Tubing would be the appropriate size Todetermine the additional charge required multiply the linear feet of liquid line to the refrigerant correction factor and subtract the factory charge for the line set 72 x 36 27 36 25 x 55 13 75 13 6 02 additional charge Tocalculated the correct subcooling for this application Refer to spec sheet or technical service manual for the design subcooling value RSD36 design subcooling is 9 F Add 4 4 F for the liquid line friction loss subtract 4 3 F for the elevation change less 2 F equals 7 1 the des
49. for continuity pin to pin If no continuity is indicated the thermal limit over load device may be open Allow motor to cool and retest 3 pin motor connector 16 pin connector 5 pin connector 17 SERVICING S 17 CHECKING COMPRESSOR WINDINGS 4 WARNING HERMETIC COMPRESSOR ELECTRICAL TERMINAL VENTING CAN BE DANGEROUS WHEN INSULATING MATERIAL WHICH SUPPORTS A HERMETIC COM PRESSOR ELECTRICAL TERMINAL SUDDENLY DISINTEGRATES DUE TO PHYSICAL ABUSE OR ASA RESULT OF AN ELECTRICAL SHORT BETWEEN THE TERMINAL AND THE COMPRESSOR HOUSING THE TERMINAL MAY BE EXPELLED VENTING THE VAPOROUS AND LIQUID CONTENTS OF THE COM PRESSOR HOUSING AND SYSTEM If the compressor terminal PROTECTIVE COVER gasket if required are not properly in place and secured there is a remote possibility if a terminal vents that the vaporous and liquid discharge can be ignited spouting flames several feet causing potentially severe or fatal injury to anyone in its path This discharge can be ignited external to the compressor if the terminal cover is not properly in place and if the dis charge impinges on a sufficient heat source Ignition of the discharge can also occur at the venting terminal or inside the compressor if there is sufficient contaminant air present in the system and an electrical arc occurs as the terminal vents Ignition cannot occur at the venting terminal without the presence of contaminant air and cannot occur ex
50. g radius C Calculate the equivalent length of fittings using the Fitting Losses in Equivalent Feet Chart Calculate using the recommended suction line size for each unit and long radius elbows 8 x 2 0 16 equivalent feet D Add suction line length A and equivalent feet of fittings 65 16 81 effective feet The total effective length of Suction Line is 81 feet Refer to the Suction Line Sizing Chart to determine the actual suction line required A 7 8 suction line would be recom mended inthis installation No oil return traps are needed as the coil is above the condenser F Measure liquid line length 65 ft G Count the number of liquid line elbows 8 short radius H Calculate the equivalent length of fittings using the Suction Line Elbow chart Calculate using the recom mended liquid line size for each unit LIQUID LINE 8 x 1 2 9 6 equivalent feet 1 Add liquid line length equivalent feet of fittings 65 9 6 74 6 effective feet J The total effective length of liquid line is 74 6 ft Refer to the Liquid Line Sizing Chart to determine the subcooling loss add the additional 3 F subcooling loss for the vertical rise Using 3 8 liquid line the subcooling loss is 5 4 F which is within an acceptable range so 3 8 liquid line will be used 5 SUCTION LINE gt 10 K Todetermine the additional charge required multiply the linear feet of liquid line to
51. ign subcooling for this installation is 7 1 F at the liquid line service valve 32 1st Trap 2nd Trap LIQUID LINE 4 3rd Trap 40 suction LINE SERVICING 7 Make the final charge adjustment Refer to the Unit specification sheet or technical information manual for the correct subcooling The subcooling reading must be adjusted for any elevation differences between the con denser and evaporator The super heat at the indoor coil should also be measured to verify proper operation of the TXV Adjust charge as explained in section S 103 CHARGING S 200 DUCT STATIC PRESSURES AND OR STATIC PRESSURE DROP ACROSS COIL This minimum and maximum allowable duct static pressure for the indoor sections are found in the specifications sec tion Tables are also provided for each coil listing quantity of air CFM versus static pressure drop across the coil Too great an external static pressure will result in insufficient air that can cause icing of the coil Too much air can cause poor humidity control and condensate to be pulled off the evaporator coil causing condensate leakage Too much air can also cause motor overloading and in many cases this constitutes a poorly designed system 5 201 AIR HANDLER EXTERNAL STATIC To determine proper air movement proceed as follows 1 Using a draft gauge inclined manometer measure the static pressure of the return duct at the inlet of the unit
52. ive cover and inspect for loose leads or insulation breaks in the lead wires 4 If no visual problems indicated carefully remove the leads at the compressor terminals 4 WARNING DAMAGE CAN OCCUR TO THE GLASS EMBEDDED TERMINALS IF THE LEADS ARE NOT PROPERLY REMOVED WHICH CAN RESULT IN THE TERMINAL VENTING AND HOT OIL DISCHARGING Carefully retest for ground directly between compressor terminals and ground 5 If ground is indicated replace the compressor S 17C Operation Test Ifthe voltage capacitor overload and motor winding test fail to show the cause for failure 4 WARNING Disconnect Electrical Power Supply 1 Remove unit wiring from disconnect switch and wire test cord to the disconnect switch NOTE The wire size ofthe test cord must equal the line wire size and the fuse must be of the proper size and type 2 Withthe protective terminal cover in place use the three leads to the compressor terminals that were discon nected at the nearest point to the compressor and connect the common start and run clips to the respec tive leads 3 Connect good capacitors of the right MFD and voltage rating into the circuit as shown 4 With power ON close the switch 4 WARNING LINE VOLTAGE NOW PRESENT A If the compressor starts and continues to run the cause for failure is somewhere else in the system B If the compressor fails to start replace Compressor Serial Number Identification COPELAND C
53. le is in the thermostat or wiring 4 Check the continuity of the thermostat and wiring Re pair or replace as necessary NOTE Consideration must be given to how the heaters are wired O D T and etc Also safety devices must be checked for continuity S 3B Cooling Anticipator The cooling anticipator is a small heater resistor in the thermostat During the off cycle it heats the bimetal element helping the thermostat call for the next cooling cycle This prevents the room temperature from rising too high before the system is restarted A properly sized anticipator should maintain room temperature within 1 1 2 to 2 degree range The anticipator is supplied in the thermostat and is not to be replaced If the anticipator should fail for any reason the thermostat must be changed S 3C Heating Anticipator The heating anticipator is a wire wound adjustable heater which is energized during the ON cycle to help prevent overheating of the conditioned space The anticipator is a part of the thermostat and if it should fail for any reason the thermostat must be replaced See the following tables for recommended heater anticipator setting in accordance to the number of electric heaters installed HEATER KIT ANTICIPATOR TABLE CB C D EHK_B C D 5 7 10 15 20 25 30 EATER KW 48 7 2 96 144 19 2 24 28 8 FIRST STAGE 0 4 0 4 0 4 04 04 04 0 4 0 4 0 4 04 04 04 0 4 0 4 5 4 CHECKING TRANSFORMER AND CONTROL
54. liquid service valve at the front of the unit 3 Record the gauge pressure and the temperature of the line 4 Reviewthe technical information manual or specfication sheet for the model being serviced to obtain the design subcooling and hi pressure values 5 Compare the hi pressure reading to the Required Liq uid Line Temperature chart left Find the hi pressure value on the left column follow that line right to the collum under the design subcooling value where the two intersect is the required liquid line temperature Alternantly you can convert the liquid line pressure gauge reading to temperature by finding the gauge reading in Temperature Pressure Chart and reading to the left find the temperature in the F Column 6 The difference between the thermometer reading and pressure to temperature conversion is the amount of subcooling 25 SERVICING Pressure vs Temperature Chart R 410A 2 2 4 4 2 4 6 8 0 2 4 6 8 0 2 4 6 8 8 0 6 2 4 4 3 6 1 Based on ALLIED SIGNAL Data 26 Co 1 A OlO NIP 109 CO OJ O1f OD Oo i i lt ojo i i 402 0 117 gt 404 0 117 406 0 118 1 408 0 118 410 0 118 412 0 119 414 0 119 416 0 119 418 0 120 3 PSIG F 420 0 422 0 424 0 426 0 428 0 430 0 432 0 434 0 436 0 438 0
55. m as required NOTE At least twelve 12 inches of the suction line immediately out of the compressor stub must be discarded due to burned residue and contaminates 1 Remove compressor discharge line strainer 2 Remove the liquid line drier and expansion valve 3 Purge all remaining components with dry nitrogen or carbon dioxide until clean 4 Install new components including liquid line drier 5 Braze all joints leak test evacuate and recharge sys tem 6 Startup the unit and record the pressure drop across the drier 7 Continue to run the system for a minimum of twelve 12 hours and recheck the pressure drop across the drier Pressure drop should not exceed 6 PSIG 8 Continue to run the system for several days repeatedly checking pressure drop across the suction line drier If the pressure drop never exceeds the 6PSIG the drier has trapped the contaminants Remove the suction line drier from the system SERVICING 9 If the pressure drop becomes greater then it must be replaced and steps 5 through 9 repeated until it does not exceed 6 PSIG NOTICE Regardless the cause for burnout must be deter mined and corrected before the new compressor is started S 120 REFRIGERANT PIPING The piping of a refrigeration system is very important in relation to system capacity proper oil return to compressor pumping rate of compressor and cooling performance of the evaporator POE oils maintain a consistent viscosi
56. matically cut in close at approximately 85 PSIG Test for continuity using VOM and if not as above replace the control S 15 CHECKING CAPACITOR CAPACITOR RUN A run capacitor is wired across the auxiliary and main windings of asingle phase permanent split capacitor motor The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor This is accomplished by using the 90 phase relationship between the capacitor current and voltage in conjunction with the motor windings so that the motor will give two phase operation when connected to a single phase circuit The capacitor also reduces the line current to the motor by improving the power factor The line side of this capacitor is marked with COM and is wired to the line side of the circuit CAPACITOR START SCROLL COMPRESSOR MODELS In most cases hard start components are not required on Scroll compressor equipped units due to a non replaceable check valve located in the discharge line of the compressor However in installations that encounter low lock rotor volt age a hard start kit can improve starting characteristics and reduce light dimming within the home Only hard start kits approved by Amana or Copeland should be used Kick Start and or Super Boost kits are not approved start assist devices The discharge check valve closes off high side pressure to the compressor after shut down allowing equalization
57. me cases of insufficient indoor air can cause icing of the indoor coil and liquid return to the com pressor but the head pressure would be lower There are other causes for high head pressure which may be found in the Service Problem Analysis Guide If other causes check out normal overcharge or asystem containing non condensables would be indicated If this system is observed 1 Start the system 2 Remove and capture small quantities of gas from the suction line dill valve until the head pressure is reduced to normal 3 Observe the system while running a cooling perfor mance test if a shortage of refrigerant is indicated then the system contains non condensables S 115 NON CONDENSABLES If non condensables are suspected shut down the system and allow the pressures to equalize Wait at least 15 minutes Compare the pressure to the temperature of the coldest coil sense this is where most of the refrigerant will be Ifthe pressure indicates a higher temperature than that of the coil temperature non condensables are present Non condensables are removed from the system by first removing the refrigerant charge replacing and or installing liquid line drier evacuating and recharging S 116 COMPRESSOR BURNOUT When acompressor burns out high temperature develops causing the refrigerant oil and motor insulation to decom pose forming acids and sludge 28 If a compressor is suspected of being burned out attach a
58. ny one motor speed lead can be connected to the idle speed tap With the thermostat in the FAN AUTO position the board allows the motor to operate at the idle speed during system off cycles for minimum circulation air When the thermostat is switched to the FAN ON position the blower motor will operate at heating cooling speed BBC High Efficiency Blower Section Sequence of Operation It is important to note that the operational logic for the control board for the BBC s is different from the BBA board hence they are not interchangeable The BBC s use the variable speed to maintain constant CFM However the BBC s control board logic changes the CFM in response to over temperature and under tem perature conditions with help from the discharge air tem perature readings from the discharge air thermistor BBC Cooling Only Operations With the thermostat the FAN AUTO position and a Y or G call the blower ramps up to speed After a 3 minute period if the supply thermistor senses the acceptable cool ing operation temperature range of 50 to 75 F the control maintains the preset CFM setting If the supply air temperature is above the acceptable range 75 F the control logic decreases the CFM If the supply temperature is below the acceptable temperature the con trol increases the CFM On the next Y or call the CFM will return to the preset level BBC Electric Heat
59. oils are designed for horizontal applications All Amana R410A installations require an R410A rated TXV for proper operation BBA and BBC blower cabinets are designed as a two piece blower coil Either the BBA or BBC blower section can be attached to CA FC CH FC or CF FC cased evapo rator coil This two piece arrangement allows for a variety of mix matching possibilities providing greater flexibility The BBC blower cabinet uses a variable speed motor that maintains a constant airflow despite duct static It is ap proved for applications with cooling coils of up to 0 8 inches W C external static pressure and includes a feature that allows airflow to be changed by 15 The BBC is intended to be used with a cased evaporator coil and a condensing unit or heat pump The blower section of the cabinet can also be used as an electric furnace The electric heating elements are field installed Electric heater kits EHK B C D and ECB_B C D are available as sales accessories for supplemental electric heat The BBA and BBC blower cabinets can be positioned for upflow counterflow horizontal right or horizontal left opera tion All units are constructed with R 4 2 insulation Inareas of extreme humidity greater than 80 consistently the installer should insulate the exterior of the blower with insulation having a vapor barrier equivalent to ductwork insulation providing local codes permit SYSTEM OPERATION COOLING CYCLE Indo
60. on line service valve 2 Install a low side pressure gauge on the suction line service valve at the outdoor unit 3 Record the gauge pressure and the temperature of the line 4 Convertthe suction pressure gauge reading to tempera ture by finding the gauge reading in Temperature Pressure Chart and reading to the left find the tempera ture in the F Column 5 The difference between the thermometer reading and pressure to temperature conversion is the amount of superheat EXAMPLE a Suction Pressure 143 b Corresponding Temp F 50 c Thermometer on Suction Line 61 F To obtain the degrees temperature of superheat subtract 50 0 from 61 0 F The difference is 11 Superheat The 11 Superheat would fall in the range of allowable superheat SUPERHEAT ADJUSTMENT The expansion valves used on Amana coils are factory set and are not field adjustable If the superheat setting be comes disturbed replace the valve S 109 CHECKING SUBCOOLING Refrigerant liquid is considered subcooled when its tem perature is lower than the saturation temperature corre sponding to its pressure The degree of subcooling equals the degrees of temperature decrease below the saturation temperature at the existing pressure 1 Attach an accurate thermometer or preferably thermo couple type temperature tester to the liquid line as it leaves the condensing unit 2 Install a high side pressure gauge on the high side
61. or Coil COOLING The refrigerant used in the system is R410A It is a clear colorless non toxic non irritating liquid R410A is a 50 50 blend of R 32 and R 125 The boiling point at atmospheric pressure is 62 9 F A few of the important principles that make the refrigeration cycle possible are heat always flows from a warmer to a cooler body under lower pressure a refrigerant will absorb heat and vaporize at a low temperature the vapors may be drawn off and condensed at a higher pressure and tempera ture to be used again The indoor evaporator coil functions to cool and dehumidify the air conditioned spaces through the evaporative process taking place within the coil tubes NOTE The pressures and temperatures shown in the refrigerant cycle illustrations on the following pages are for demonstration purposes only Actual temperatures and pressures are to be obtained from the Expanded Perfor mance Chart Liquid refrigerant at condensing pressure and tempera tures 428 psig and 122 F leaves the outdoor condensing coil through the drier and is metered into the indoor coil through the metering device As the cool low pressure saturated refrigerant enters the tubes of the indoor coil a portion of the liquid immediately vaporizes It continues to soak up heat and vaporizes as it proceeds through the coil cooling the indoor coil down to about 48 F 6 Outdoor Coil Thermostatic Expansion Valve
62. otal or 1 3 and 2 3 the way up the riser 3 traps total 3 Estimate the effective length of pipe Remember each trap will have a substantial equivalent length The suction line effective length could therefore be consider ably greater than the liquid line effective length 29 SERVICING Oil Trap Construction and Equivalent Lengths 5 Size the liquid line per the Liquid Line Sizing charts Ifthe evaporator coil is above the condensing unit you must add the subcooling loss for the vertical rise to the liquid line friction loss If the evaporator coil is below the condenser you may subtract the subcooling increase from the friction line loss The subcooling loss or gain is 1 F for every 10 feet of change in vertical height In any application the subcooling loss 2 F cannot ex Long Radius 90 ceed the system design subcooling LIQUID LINE SIZING Liquid line subcooling loss for R410a due to Pressure Drop degree F line equiv length feet 45 Street Ell lt 45 Ell Tonnage 75 100 a 5 0 2 5 90 Street Ell Friction loss for oil trap Equivalent lg in feet Dia Diy I jo I jo gt D 5 8 Trap 3 7 Ft 3 4 Trap 4 6 Ft 7 8 Trap 5 3 Ft 1 1 8 Trap 5 9 Ft 6 Determine the amount of additional refrigerant the sys tem will require using the Refrigerant Correction Chart REFRIGERANT CORRECTION CHART 4 Size the suction line
63. per the Suction Line Sizing Chart Remember you want to balance the size selection A smaller line size will improve oil return but reduce capacity A larger line size will minimize capacity loss but oil return may be an issue SUCTION LINE SIZING 7 oe is not normally required in R410A sys Cooling capacity loss with long line sets percentage of total capacity loss line equiv length feet Vapor Line 75 100 125 150 175 2 5 8 4 0 4 7 6 9 7 9 3 4 2 0 3 0 3 8 4 5 5 0 5 8 4 4 5 6 6 7 7 9 9 1 2 5 3 4 4 2 1 9 2 7 3 5 41 4 8 7 8 1 1 2 0 2 8 3 4 3 9 5 8 6 0 7 6 9 3 10 9 12 4 3 3 4 i 2 6 3 6 4 5 5 6 6 4 7 8 2 0 2 7 3 3 3 8 4 5 3 5 3 4 3 2 4 3 5 3 6 2 71 7 8 0 0 1 7 2 1 2 4 2 7 2 9 4 3 4 0 5 2 3 5 5 0 6 3 7 4 8 5 7 8 0 0 2 0 3 0 3 8 4 4 5 3 3 4 1 5 3 3 5 4 7 1 8 9 10 2 11 8 5 7 8 0 0 2 2 4 3 6 4 9 5 8 6 9 11 8 0 0 0 0 1 0 1 5 1 8 2 3 2 8 30 SERVICING REFRIGERANT LINE SIZING Known Factors 1 RSD48A2A and CA48TCC coil TX41004A expansion valve Evaporator above Condenser 2 Liquid Line 65 linear feet w 8 long radius elbows and 30 ft vertical lift 3 Suction Line 65 linear feet w 8 long radius elbows Determine Suction and Liquid Line sizes Procedures A Measure length of suction line 65 ft B Countthe number of suction line elbows 8 lon
64. place Open reading replace Start capacitor would read resistor resistance 16 S 15B Capacitance Check Using a hookup as shown below take the amperage and voltage readings and use them in the formula VOLTMETER CAPACITOR TESTING CAPACITANCE 4 WARNING DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING Capacitance MFD 2650 X Amperage Voltage S 16A CHECKING FAN AND BLOWER MOTOR WINDINGS PSC MOTORS The auto reset fan motor overload is designed to protect the motor against high temperature and high amperage condi tions by breaking the common circuit within the motor similar to the compressor internal overload However heat generated within the motor is faster to dissipate than the compressor allow at least 45 minutes for the overload to reset then retest 4 WARNING Disconnect Electrical Power Supply 1 Remove the motor leads from its respective connection points and capacitor if applicable 2 Check the continuity between each of the motor leads 3 Touch one probe of the ohmmeter to the motor frame ground and the other probe in turn to each lead If the windings do not test continuous or a reading is obtained from lead to ground replace the motor SERVICING S 16B CHECKING FAN AND BLOWER MOTOR ECM MOTORS An ECM is an Electronically Commutated Motor which offers many significant advantages over PSC motors The ECM has near zero roto
65. probe measure amperage and voltage Refrigeration test cord check compressors motors and continuity testing 5 Volt Ohm meter testing continuity capacitors and motor windings 6 Accurate Leak Detector testing for refrigerant leaks High evacuation pump evacuation ONCE A YEAR Qualified Service Personnel Only 1 Clean the indoor and outdoor coils 2 Clean the casing of the outdoor unit inside and out 3 Motors used on Amana products are considered to be permanently lubricated and do not require lubrication Most current motors no longer have oil ports on the motors 4 Manually rotate the outdoor fan and indoor blower to be sure they run freely 5 Inspect the control panel wiring compressor connections and all other component wiring to be sure all connec tions are tight Inspect wire insulation to be certain that it is good 6 Check the contacts of the compressor contactor If they are burned or pitted replace the contactor 7 Using a halide or electronic leak detector check all pip ing and etc for refrigerant leaks 8 Start the system and run a Cooling Performance Test If the results of the test are not satisfactory see the Ser vice Problem Analysis Chart for the possible cause 8 Electric vacuum gauge manifold and high vacuum hoses to measure and obtain proper vacuum 9 Accurate charging cylinder or electronic scale mea sure proper refrigerant charge 10 Inclined manometer
66. r loss synchronous machine opera tion variable speed low noise and programmable air flow Because of the sophisticated electronics within the ECM motor some technicans are intimated by the ECM motor however these fears are unfounded GE offers two ECM motor testers and with a VOM meter one can easily perform basic troubleshooting on ECM motors An ECM motor requires power line voltage and a signal 24 volts to operate The ECM motor stator contains permanent mag net As a result the shaft feels rough when turned by hand This is a characteristic of the motor not an indication of defective bearings 4 WARNING LINE VOLTAGE NOW PRESENT 1 Disconnect the 5 pin connector from the mo tor 5 D 2 Using a volt meter check for line voltage at O terminals 4 amp 5 atthe power connector If no voltage is present 3 Checkthe unitfor incoming power See section S 1 4 Check the control board See section S 40 5 Iflinevoltage is present reinsert the 5 pin connector and remove the 16 pin connector 6 Check for signal 24 volts at the transformer 7 Check for signal 24 volts from the thermostat the terminal at the 16 pin connector 8 Using ohmmeter check for continuity from the 1 amp 3 common pins to the transformer neutral or C thermostat terminal If you do not have continuity the motor may function erratically Trace the common cir cuits locate and repair
67. rical Power Supply 1 Check wiring visually for signs of overheating damaged insulation and loose connections Use to check continuity of any suspected open wires w If any wires must be replaced replace with comparable gauge and insulation thickness S 3 CHECKING THERMOSTAT WIRING AND ANTICIPATOR THERMOSTAT WIRE SIZING CHART LENGTH OF RUN MIN COPPER WIRE GAUGE AWG S 3A Thermostat and Wiring 4 WARNING LINE VOLTAGE NOW PRESENT With power ON thermostat calling for cooling 1 Use a voltmeter to check for 24 volts at thermostat wires C and Y in the condensing unit control panel N No voltage indicates trouble in the thermostat wiring or external transformer source 3 Check the continuity of the thermostat and wiring Re pair or replace as necessary Indoor Blower Motor With power ON 4 WARNING LINE VOLTAGE NOW PRESENT 1 Set fan selector switch at thermostat to ON position 2 With voltmeter check for 24 volts at wires C and G 3 No voltage indicates the trouble is in the thermostat or wiring 4 Check the continuity of the thermostat and wiring Re pair or replace as necessary Resistance Heaters 1 Set room thermostat to a higher setting than room temperature so both stages call for heat With voltmeter check for 24 volts at each heater relay Note BBA BBC heater relays are DC voltage SERVICING 3 No voltage indicates the troub
68. ring numbers listed on pages 4 amp 5 Model and Manufactu RSD Model Remote Coolers with R410A Refrigerant service Instructions Blowers Coils amp Accessories rn AK AES YAV fy OY gt RS6100003 ry 2002 Janua ing anao amp Air Condition Bogos 9 Heat 5 ceo Comfort Quality Trust Table of Contents PRODUCT 4 PRODUCT 5 SYSTEM OPERATION a 6 7 ACCESSORIES 8 SCHEDULED MAINTENANCE 9 SERVICING 9 33 WIRING SCHEMATICS teenie ined sine tied aie Sere ies 34 36 IMPORTANT INFORMATION Pride and workmanship go into every product to provide our customers with quality products It is possible however that during its lifetime a product may require service Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools parts testing instruments and the appropriate service manual REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS
69. st between 5 and 6 should read open 5 If not as above replace the relay SERVICING S 12 CHECKING HIGH PRESSURE CONTROL The high pressure control capillary senses the pressure in the compressor discharge line If abnormally high condens ing pressures develop the contacts of the control open breaking the control circuit before the compressor motor overloads This control is automatically reset 4 WARNING Disconnect Electrical Power Supply 1 Using an ohmmeter check across terminals of high pressure control with wire removed If not continuous the contacts are open 3 Attach a gauge to the dill valve port on the base valve With power ON 4 WARNING LINE VOLTAGE NOW PRESENT 4 Startthe system and place a piece of cardboard in front of the condenser coil raising the condensing pressure Check pressure at which the high pressure control cuts out LIQUID LINE AUTOMATIC RESET If it cuts out at610 PSIG 10 PSIG itis operating normally See causes for high head pressure in Service Problem Analysis Guide If it cuts out below this pressure range replace the control S 13 CHECKING LOW PRESSURE CONTROL The low pressure control senses the pressure in the suction line and will open its contacts a drop pressure The low pressure control will automatically reset itself with a rise in pressure The low pressure control is designed to cut out open at approximately 50 PSIG It will auto
70. ternally from the venting terminal without the presence of an exter nal ignition source Therefore proper evacuation of a hermetic system is essential at the time of manufacture and during servicing To reduce the possibility of external ignition all open flame electrical power and other heat sources should be extin guished or turned off prior to servicing a system If the following test indicates shorted grounded or open windings see procedures S 19 for the next steps to be taken S 17A Resistance Test Each compressor is equipped with an internal overload The line break internal overload senses both motor amper age and winding temperature High motor temperature or amperage heats the disc causing it to open breaking the common circuit within the compressor on single phase units Heat generated within the compressor shell usually due to recycling of the motor high amperage or insufficient gas to cool the motor is slow to dissipate Allow at least three to four hours for it to cool and reset then retest Fuse circuit breaker ground fault protective device etc has not tripped 18 4 WARNING Disconnect Electrical Power Supply 1 Remove the leads from the compressor terminals 4 WARNING SEE WARNING S 17 PAGE 26 BEFORE REMOVING COMPRESSOR TERMINAL COVER 2 Using an ohmmeter test continuity between terminals S R C R and C S on single phase units or terminals T2 T2 and on 3 phase units OHM
71. the nominal blower speed selected 7 dG 9 a0lMHA 2 0 VSOVOLPXL Vrovolpxl VEOVOLPXL VLOVOLPXL aso VSOMLV VLOOSV 3 2142919 9199 3 9199 3 919913 2142919 919913 9199 3 yy 9 9 L Not used in this application or not available gt gt xx xf xx gt gt 2 1 2 195 enep 195 VOLVY LL sult 10 depy HEIS HEIS punog 10 409 yy 72 5 5 x x lt lt z BI 2 DINDIAIDIOIO
72. through the scroll flanks Equalization requires only about 2second prevent the compressor from short cycling a Time Delay Relay Cycle Protector has been added to the low voltage circuit RELAY START A potential or voltage type relay is used to take the start capacitor out of the circuit once the motor comes up to speed This type of relay is position sensitive The normally closed contacts are wired in series with the start capacitor and the relay holding coil is wired parallel with the start winding As the motor starts and comes up to speed the increase in voltage across the start winding will energize the start relay holding coil and open the contacts to the start capacitor 15 SERVICING Two quick ways to test a capacitor are a resistance and a capacitance check START CAPACITOR RUN CAPACITOR CONTACTOR HARD START KIT WIRING S 15A Resistance Check 4 WARNING Disconnect Electrical Power Supply 1 Discharge capacitor and remove wire leads 4 WARNING DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING CAPACITOR TESTING CAPACITOR RESISTANCE 2 Setan ohmmeter on its highest ohm scale and connect the leads to the capacitor A Good Condition indicator swings to zero and slowly returns to infinity Start capacitor with bleed resistor will not return to infinity It will still read the resistance of the resistor B Shorted indicator swings to zero and stops there re
73. ts no danger to anyone providing the terminal protective cover is properly in place If however the terminal protective cover is not properly in place a venting terminal may discharge a combination of a hot lubricating oil and refrigerant b flammable mixture if system is contaminated with air in a stream of spray which may be dangerous to anyone in the vicinity Death or serious bodily injury could occur Under no circumstances is a hermetic compressor to be electrically energized and or operated without having the terminal protective cover properly in place See Service Section S 17 for proper servicing PRODUCT IDENTIFICATION This section will identify the models that are covered Remote Cooling S Alternate Refrigerant D 13 Seer Outdoor Units Featuring cubed coil design and low speed fan motors for quieter operation R410A refrigerant Coil A style coil design designator indicates flowrator installed All R410A applications require a R410A rated TXV Up flow counter flow applications Cased and uncased models P1237303C P1237305C Coil slab coil design designator indicates flowrator installed All R410A applications require a R410A rated TXV P1237005C P1237114C Coil dedicated Horizontal A coil design designator indicates flowrator installed All 08 R410A applications require R410A rated TX410A A P1236901C P1236906C Thermo eXpansion valve R
74. ty over a large tem perature range which aids in the oil return to the compressor however there will be some installations which require oil return traps These installations should be avoided when ever possible as adding oil traps to the refrigerant lines also increases the opportunity for debris and moisture to be introduced into the system The maximum length of tubing to be used with a remote Condenser system is 175 feet 1 All horizontal suction line runs must be pitched towards the compressor one inch per ten feet This aids the return of the oil to the compressor 2 Avoid long running traps in horizontal suction line 3 The liquid line must not be attached to an uninsulated suction line 4 Ifthe liquid line is routed through an area which has an ambient higher than 120 F then that portion of the liquid line must be insulated 5 Suction line sizes should allow for sufficient internal line velocity to return oil to the compressor An oil trap by the indoor coil may be necessary to aid in oil return when the outdoor unit is located above the indoor coil 6 In sizing refrigeration piping determine the number of 90 and 45 elbows required and add their equivalent lengths to the length of straight pipe Find the equivalent length of fittings in the following table EQUIVALENT LENGTH IN FEET SUCTION LINE ELBOWS 3 8 1 2 5 8 3 4 7 8 1 1 8 Sweat Copper ortong Rade oa oa 15 17 45 0 4 0

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