Friedrich KM18J30A Air Conditioner User Manual
Contents
1. 1998 QuietMaster J Series KS10J10 KS12J10 KS12J30A KM18J30A KM21J30 KL25J30 Service amp Parts Manual TABLE OF CONTENTS GENERAL Friedrich Room Model Number Code Application and Sizing Instructions for using Cooling Load Estimate Form Cooling Load Estimate Form SPECIFICATIONS PERFORMANCE DATA Specifications KS KM KL Models Performance Data KS KM KL Models COMPONENTS OPERATION TESTING Compressors Thermal Overload External Thermal Overload Internal Fan Motor Run Capacitor System Control Switch KS KM amp KL Models Thermostat KS KM amp KL Models Thermostat Adjustment Resistor MoneySaver Switch Rocker Switch Sealed Refrigeration System Repairs Hermetic Component Replacement Special Procedure in the case of Motor Compressor Burn Out Rotary Compressor Special Troubleshooting amp Service Refrigerant Charge TROUBLESHOOTING Troubleshooting Cooling WIRING DIAGRAMS 618 200 00 618 200 00 618 200 00 618 200 00 618 200 00 618 200 00 PARTS LIST KS KM Series Chassis Parts KS KM Series Cabinet Parts KS KM Series Parts List KL Series Chassis Parts KL Series Cabinet Parts KL Series Parts List FRIEDRICH ROOM MODEL NUMBER CODE K S 10 G 1 0 D 1st DIGIT FUNCTION _ S Str2. It is necessary only to insert the proper measurements on the lines provided and multiply by the given factors then add the result for the total load require ments Cooling load requirements are generally based on the cooling load for comfortable air conditioning which does not require specific conditions of inside temperature and humidity The load calculation form is based on outside design temperature of 95 FDB and 75 FWB It can be used for areas in the Continental United States having other outside design temperatures by applying a correction factor for the particular locality as determined from the map shown on Page 6 When sizing a TwinTemp unit for cooling and heating we must remember that the heating capacity of any given unit varies directly with the outdoor ambient temperature Also we must keep in mind the average low temperatures which might be experienced in the locality where the unit is to be installed Therefore when sizing a TwinTemp unit both cooling and heating requirements must be calculated Do not oversize or undersize one phase of the units capacity at the expense of the other In those cases where the unit will provide satisfactory cooling at all times but will be inadequate for those few times that the outdoor temperature is below the maximum low for the unit additional auxil iary heating facilities must be provided to insure that adequate heat is available at all times INSTRUCTIONS FOR USING COOLING LOAD ESTIMAT
3. or exhaust air door Close doors Instruct customer on use of this feature open on applicable models Compressor not pumping Check amperage draw against nameplate If not conclu properly sive make pressure test Page 15 PROBLEM POSSIBLE CAUSE TO CORRECT Fuse blown or circuit tripped Replace fuse reset breaker Ifrepeats check fuse or breaker size Check for shorts in unit wiring and compo nents 20 1200 0000 Loose or disconnected wiring at Check wiring and connections Reconnect per wiring switch or other components diagram PROBLEM POSSIBLE CAUSE TO CORRECT Dirty filter Clean as recommended in Owener s Manual Restricted air flow Check for dirty or obstructed coil clean as required Evaporator coil Inoperative thermostat Test for shorted thermostat or stuck contacts freezes up Short of refrigerant De ice coil and check for leak Inoperative fan motor Test fan motor and replace if inoperative Partially restricted capillary De ice coil Check temperature differential across coil Touch test coil return bends for same temperature Test for low running current PROBLEM POSSIBLE CAUSE TO CORRECT Excessive heat load Unit undersized Test cooling performance of unit Re place with larger unit Restriction in line Check for partially iced coil Check temperature split continually Does not Refrigerant leak Check for oil at silver soldered connections Check for cycle off partially i
4. thermostat to coldest position Test thermostat and enough or inoperative replace if inoperative ompressor hums but cuts o Hard start compressor Direct test compressor If com Compressor does not zn on overload pressor starts add starting components Open or shorted compressor windings Open overload Test overload protector and replace if inoperative Open capacitor Test capacitor and replace if inoperative Inoperative system switch Test for continuity in all positions Replace if inoperative Broken loose or incorrect Refer to appropriate wiring diagram to check wiring wiring PROBLEM POSSIBLE CAUSE TO CORRECT Inoperative system switch Test switch and replace if inoperative Broken loose or incorrect Refer to applicable wiring diagram Fan motor does not wiring run Open capacitor Test capacitor and replace if inoperative Fan speed switch open Test switch and replace if inoperative Inoperative fan motor Test fan motor and replace if inoperative be sure internal overload has had time to reset PROBLEM POSSIBLE CAUSE TO CORRECT Undersized unit Refer to Sizing Charts Thermostat open or inopera Setto coldest position Test thermostat and replace if tive necessary Dirty filter Clean as recommended in the Owner s Manual Does not cool or evaporator coil cools only slightly Pool air circulation in area Adjust discharge air louvers Use high fan speed being cooled Fresh air
5. 18 047 00 618 025 00 618 041 00 618 036 00 618 049 00 618 026 00 Brace Shroud 618 169 00 Insulation Inner Wall 618 169 01 Insulation Inner Wall 618 173 00 Blower Front 618 174 00 Blower Front 618 149 00 Scroll 618 175 00 Scroll 618 215 00 Door Slide Assembly 618 034 05 Base Pan 618 034 18 Base Pan 618 034 01 Base Pan 618 038 00 Drain Pan 618 188 00 Rear Grille 618 188 01 Rear Grille 610 289 00 Grommet Compressor 01150934 Grommet Compressor Not Shown 4 Capillary length may vary flow rate is the same Page 23 PART NO QUIETMASTER KS KM SERIES PARTS LIST DESCRIPTION APPLICATION 914 004 00 618 102 00 618 093 00 618 092 00 618 062 00 618 063 00 618 063 01 618 257 00 618 257 01 618 089 00 618 111 00 618 196 00 618 199 00 602 944 08 602 944 09 611 050 04 611 050 05 611 095 03 618 197 01 618 198 01 618 198 03 606 103 03 608 460 16 617 173 01 618 116 03 618 116 04 618 139 00 618 118 00 618 118 01 618 141 01 600 733 00 01900 235 01900 312 Not Shown Page 24 gt amp N gt CHASSIS PARTS Cont Bolt Compressor Mounting Plenum Assembly Knob Fresh Air amp Exhaust Lever Fresh Air amp Exhaust Connector Louver Louver Grille Louver with Handle Outer Shell with Sill Plate Outer Shell with Sill Plate Grille Intake Grille Intake Guide Shell Latch Intake Grille Wingboard Wingboard Access
6. 760520 03760545 03760479 603 081 01 614 939 05 618 072 00 618 110 00 600 713 12 zi Not Shown ELECTRICAL PARTS Compressor Tecumseh 115 V 60 Hz 1 Ph Model RK5510E Compressor Tecumseh 115 V 60 Hz 1 Ph Model RK5512E Compressor Tecumseh 115 V 60 Hz 1 Ph Model RK5512EXD Compressor Bristol 230 208 V 60 Hz 1 Ph Model H23B175ABCC Compressor Tecumseh 230 208 V 60 Hz 1 Ph Model AWF5522EXN Overload Compressor MRA3790 114 Overload Compressor MRA4703 117 Overload Compressor MRA3794 114 Overload Compressor MRA98982 117 Motor Fan Motor Fan Motor Fan Motor Fan Cord Electric Supply 15 Amp 125 Volt Cord Electric Supply 15 Amp 125 Volt Cord Electric Supply 15 Amp 250 Volt Cord Electric Supply 20 Amp 250 Volt System Switch Rocker Switch Thermostat Capacitor Run 25 10 MFD 370 V Capacitor Run 25 7 5 MFD 370 V Capacitor Run 35 7 5 MFD 370 V Harness Wire Compressor Harness Wire Compressor Harness Wire Compressor Harness Wire Fan Motor Resistor Block 115 V Resistor Block 230 V REFRIGERATION SYSTEM COMPONENTS Coil Evaporator Coil Evaporator Coil Evaporator Coil Evaporator Coil Condenser Coil Condenser t Capillary Tube 059 I D x 34 39 Long t Capillary Tube 059 I D x 31 5 8 35 Long Capillary Tube 042 I D x 20 Long Capillary Tube 049 I D x 44 Long Filter Drier use when repairing sealed syste
7. E FORM FOR ROOM AIR CONDITIONERS AHAM PUB NO RAC 1 A This cooling load estimate form is suitable for estimating the cooling load for comfort air conditioning installations which do not require specific conditions of inside temperature and humidity B The form is based on an outside design temperature of 95 F dry bulb and 75 F wet bulb It can be used for areas in the continental United States having other outside design temperatures by applying a correction factor for the particular locality as determined from the map C The form includes day factors for calculating cooling loads in rooms where daytime comfort is desired Such as living rooms offices etc D The numbers of the following paragraphs refer to the corresponding numbered item on the form 1 Multiply the square feet of window area for each exposure by the applicable factor The window area is the area of the wall opening in which the window is installed For windows shaded by inside shades or venetian blinds use the factor for Inside Shades For windows shaded by outside awnings or by both outside awnings and inside shades or venetian blinds use the factor for Outside Awnings Single Glass in cludes all types of single thickness windows and Double Glass includes sealed airspace types storm windows and glass block Only one number should be entered in the right hand column for Item 1 and this number should represent only the exposure with th
8. NNECT ELECTRICAL POWER TO UNIT BEFORE SERVICING OR TESTING COMPRESSORS Compressors are single phase 15 or 230 208 volt de pending on the model unit All compressor motors are permanent split capacitor type using only a running ca pacitor across the start and run terminal All compressors are internally spring mounted and ex ternally mounted on rubber isolators COMPRESSOR WINDING TEST See Figure 1 Remove compressor terminal box cover and disconnect wires from terminals Using an ohmmeter check conti nuity across the following 1 Terminal C and S no continuity open wind ing replace compressor 2 Terminal C and R no continuity open wind ing replace compressor 3 Terminal R and S no continuity open wind ing replace compressor Figure 1 Compressor Winding Test ae Page 8 GROUND TEST Use an ohmmeter set on its highest scale Touch one lead to the compressor body clean point of contact as a good connection is a must and the other probe in turn to each compressor terminal see Figure 2 If a reading is obtained the compressor is grounded and must be replaced Figure 2 Typical Ground Test CHECKING COMPRESSOR EFFICIENCY The reason for compressor inefficiency is normally due to broken or damaged suction and or discharge valves reducing the ability of the compressor to pump refriger ant gas This condition can be checked as foll
9. RD II TO CAPACITOR BRACKET TO CAPACITOR BRACKET TO CHASSIS 6 WAY MULTI WIRE COLOR NOTE FOR PIN CONNECTOR ANTICIPATOR RESISTOR 115V 60HZ WHITE 230 208 60HZ BLACK TO INNERWALL OR BLUE 220 240V SOHZ BLACK MOTOR MOUNT SCHEMATIC RIBBED CONDUCTOR SWITCH LOGIC ee LEGEND ANTICIPATOR RESISTOR SWITCH POSITION CIRCUIT MONEY SAVER ROCKER SWITCH CAPACITOR 1 12 4 COMPR COMPRESSOR Jr GROUND LEAD or CFO OF Of CO MTR FAN MOTOR e COMBINATION TERMINAL Lowcoo xlololo x OVLD OVERLOAD PROTECTOR O PLASTIC INSULATOR IMEDCOOL ns SYSSW SYSTEM SWITCH HI COOL X X IDT INDOOR THERMOSTAT PART NO REV FAN ONLY olxlololo 618 200 00 02 Page 19 0 x lt n A lt QO u CL Lu x lt o x a Lu gt lt F Page 20 REF PART NO QUIETMASTER KS KM SERIES PARTS LIST DESCRIPTION APPLICATION 615 628 09 615 628 00 615 628 04 617 187 01 611 935 46 603 645 98 603 645 90 603 645 96 615 780 10 610 714 80 610 714 93 610 714 94 610 714 96 605 000 54 605 000 53 605 000 51 605 000 49 606 072 03 618 061 00 618 225 00 610 803 38 610 803 37 610 803 34 618 213 00 618 214 00 618 212 00 618 208 00 618 080 00 618 080 01 N NNOO G GQ GQ 0 PY DD 618 501 01 618 501 00 618 500 05 618 500 02 618 503 03 618 502 00 01390212 03
10. T GAIN FROM QUANTITY 1 WINDOWS Heat gain from sun Northeast No Shades 60 FACTORS inside Shades 25 DAY Outside Awnings 20 BTU Hr Quantity x Factor Area x Factor Use East Southeast South Southwest West Northwest North 2 Windows Heat gain by conduction Total of all windows Single glass Double glass or glass block 3 WALLS Based on linear feet of wall a Outside walls North exposure Other than North exposure b Inside Walls between conditioned and uncondi tioned spaces only 4 ROOF OR CEILING Use one only a Roof uninsulated b Roof 1 inch or more insulation c Ceiling occupied space above d Ceiling insulated with attic space above e Ceiling uninsulated with attic space above 5 FLOOR Disregard if floor is directly on ground or over basement 6 NUMBER OF PEOPLE 7 UGHTS AND ELECTRICAL EQUIPMENT IN USE 8 DOORS AND ARCHES CONTINUOUSLY OPENED TO UNCONDITIONED SPACE Linear teet of width 9 SUB TOTAL 10 TOTAL COOLING LOAD BTU per hour to be used for selec tion of room air conditioner s _ 581 ____ sqft _sqft _ sqft ft ft sqft _ sft 80 40 25 75 30 20 75 35 110 45 20 largest go ______ load 150 65 45_____ Use 120 50 35 only 0 0 o one These factors are tor singie glass only For glass block multiply the above factors by 0 5 for double gass or storm windows muttiply the above factors by 0 8
11. Wingboard Accessory Package Bracket Support Angle Wingboard Top Angle Wingboard Side Gasket Vinyl Plastic Bag Hardware Gasket Chassis Foam Carton Shipping Pad Shipping Bottom Pad Shipping Top Pad Shipping Front amp Rear Guide Shell Gasket Window Foam IES Page 28 01900 235 01900 312 Drain Condensate Connection Kit DC 2 Start Kit Capacitor Relay Pow R Pak Use Factory Certified Parts Friedrich Air Conditioning Co 4200 North Pan Am Expressway PO Box 1540 San Antonio Texas 78295 1540 U S A Phone 210 357 4400 Fax 210 357 4480 RAC K 1 98 Page 29
12. aight Cool Value Series C Straight Cool Budget Series Y Heat Pump E Electric Strip K Straight Cool Challenger or QuietMaster Series W Thru The Wall WallMaster Series 2nd DIGIT TYPE C Casement P PowerMiser Portable Q QStar KStar orYQ TwinTemp S Small Chassis M Medium Chassis L Large Chassis W Built In H Hazardgard 3rd amp 4th DIGITS APPROXIMATE BTU HR Cooling Heating BTU HR capacity listed in Specifications Performance Data Section 5th DIGIT ALPHABETICAL MODIFIER 6th DIGIT VOLTAGE 1 115 Volts 2 230 Volts 3 230 208 Volts 7th DIGIT 0 Straight Cool amp Heat Pump Models ELECTRIC HEAT MODELS 1 1 KW Heat Strip Nominal 3 3 KW Heat Strip Nominal 4 4 KW Heat Strip Nominal 5 5 KW Heat Strip Nominal 8 8 KW Heat Strip Nominal 8th DIGIT Major Change APPLICATION AND SIZING In the application and sizing of room air conditioners for cooling it is most important to give full consideration to all factors which may contribute to the heat loss or gain ofthe space to be conditioned It is therefore necessary to make a survey of the space to be conditioned and calculate the load requirements before a selection of the size of the equipment needed can be made The load requirement may be determined very easily by simply using the standard AHAM Load Calculating Form on Page 6 This form is very easy to use and is self explanatory throughout
13. ced coil Check split across coil Check for low running amperage Thermostat contacts stuck Check operation of thermostat Replace if contacts remain closed Thermostat incorrectly wired Refer to appropriate wiring diagram PROBLEM POSSIBLE CAUSE TO CORRECT Thermostat does not Thermostat contacts stuck Replace thermostat turn unit off Thermostat set at coldest point Turn to higher temperature setting to see if unit cycles off Incorrect wiring Refer to appropriate wiring diagram Unit undersized for area to be Refer to Sizing Chart Page 16 PROBLEM POSSIBLE CAUSE TO CORRECT Overload inoperative Opens Check operation of unit Replace overload if system too soon operation is satisfactory Compressor attempts Compressor attempts to start Allow a minimum of two 2 minutes for pressures to to start or runs for before system pressures are equalize before attempting to restart Instruct customer short periods only equalized of waiting period Cycles on overload Low or fluctuating voltage Check voltage with unit operating Check for other appliances on the circuit The air conditioner should be on a separate circuit for proper voltage and be fused separately Refer to appropriate wiring diagram Shorted or incorrect capacitor Check by substituting a known good capacitor of correct rating Restricted or low air flow through Check for proper fan speed or blocked condenser condenser coil
14. e largest load 2 Multiply the total square feet of all windows in the room by the applicable factor 3a Multiply the total length linear feet of all walls exposed to the outside by the applicable factor Doors should be considered as being part of the wall Outside walls facing due north should be calculated separately from outside walls facing other directions Walls which are permanently shaded by adjacent structures should be considered North Exposure Do not consider trees and shrubbery as providing permanent shading An uninsulated frame wall or a masonry wall 8 inches or less in thickness is considered Light Construction An insulated wall or masonry wall over 8 inches in thickness is considered Heavy Construc tion 3b Multiply the total length linear feet of all inside walls between the space to be conditioned and any uncon ditioned spaces by the given factor Do not include inside walls which separate other air conditioned rooms 4 Multiply the total square feet of roof or ceiling area by the factor given for the type of construction most nearly describing the particular application use one line only 5 Multiply the total square feet of floor area by the factor given Disregard this item if the floor is directly on the ground or over a basement 6 Multiply the number of people who normally occupy the space to be air conditioned by the factor given Use a minimum of 2 people 7 Determine the total number of watt
15. ected An open capacitor will show no movement of the pointer when placed across the terminals of the capacitor SYSTEM CONTROL SWITCH A five position control switch is used to regulate the op eration of the fan motor and compressor The compres sor can be operated with the fan operating at low me dium or high speed The fan motor can also be operated independently on medium speed See switch section as indicated on decorative control panel see Figure 7 SYSTEM CONTROL SWITCH TEST Disconnect leads from control switch see Figure 8 There must be continuity as follows 1 Off Position no continuity between terminals 2 Lo Cool Position between terminals L1 and C LO and MS 3 Med Cool Position between terminals L1 and GH M and MS 4 Hi Cool Position between terminals L1 and C H and MS 5 Fan Only Position between terminals L1 and ON Figure 7 System Control Panel Figure 8 System Control Switch THERMOSTAT Figure 9 A cross ambientthermostat is used on all standard chas sis units In addition to cycling the unit in a heating or cooling operation the thermostat will terminate the cool ing cycle in the event ice forms on the evaporator coil in this case the thermostat functions as a de ice control Aresistor anticipator is positioned within a plastic block to suppl
16. he winding temperature and or cur rent draw The overload is connected in series with the common motor terminal Should the internal temperature and or current draw be come excessive the contacts in the overload will open turning off the compressor The overload will automati cally reset but may require several hours before the heat is dissipated CHECKING THE INTERNAL OVERLOAD see Figure 4 Figure 4 LINE BREAK INTERNAL OVERLOAD OHMMETER 1 With no power to unit remove the leads from the compressor terminals 2 Using an ohmmeter test continuity between ter minals C S and C R If not continuous the com pressor overload is open and the compressor must be replaced FAN MOTOR A single phase permanent split capacitor motor is used to drive the evaporator blower and condenser fan A self resetting overload is located inside the mo tor to protect against high temperature and high amperage conditions FAN MOTOR TEST 1 Determine that capacitor is serviceable 2 Disconnect fan motor wires from fan speed switch or system switch 3 Apply live test cord probes on black wire and com mon terminal of capacitor Motor should run at high speed 4 Apply live test cord probes on red wire and com mon terminal of capacitor Motor should run at low speed Figure 5 Fan Motor 5 Apply live test cord probes on each of the re maining wires from the speed switch or system switch to test
17. illary tube Proceed with processing as outlined under her metic component replacement ROTARY COMPRESSOR SPECIAL TROUBLESHOOTING AND SERVICE Basically troubleshooting and servicing rotary compres sors is the same as on the reciprocating compressor with only a few exceptions 1 Because of the spinning motion of the rotary the mounts are critical If vibration is present check the mounts carefully 2 The electrical terminals on the rotary are in a dif ferent order than the reciprocating compressors The terminal markings are on the cover gasket Use your wiring diagram to insure correct con nections REFRIGERANT CHARGE 1 The refrigerant charge is extremely critical Mea sure charge carefully as exact as possible to the nameplate charge 2 The correct method for charging the rotary is to introduce liquid refrigerant into the high side of the system with the unit off Then start compres sor and enter the balance of the charge gas only into the low side The introduction of liquid into the low side with out the use of a capillary tube will cause damage to the discharge valve of the rotary compressor NOTE All inoperative compressors returned to Friedrich must have all lines properly plugged with the plugs from the replacement compressor Page 14 Troubleshooting Cooling PROBLEM POSSIBLE CAUSE TO CORRECT Low voltage Check for voltage at compressor 1115 volt and 230 volt Thermostat not set cold Set
18. intermediate speeds CAPACITOR RUN A run capacitor is wired across the auxiliary and main winding of a single phase permanent split capacitor motor such as the compressor and fan motor A single capacitor can be used for each motor or a dual rated capacitor can be used for both The capacitor s primary function is to reduce the line current while greatly improving the torque characteris tics of a motor The capacitor also reduces the line cur rent to the motor by improving the power factor of the load The line side of the capacitor is marked with a red dot and is wired to the line side of the circuit see Figure 6 Figure 6 Run Capacitor Hook Up RED DOT RUN CAPACITOR Page 10 CAPACITOR TEST 1 Remove capacitor from unit 2 Check for visual damage such as bulges cracks or leaks 3 For dual rated apply an ohmmeter lead to com mon C terminal and the other probe to the com pressor HERM terminal A satisfactory capacitor will cause a deflection on the pointer then gradu ally move back to infinity 4 Reverse the leads of the probe and momentarily touch the capacitor terminals The deflection of the pointer should be two times that of the first check if the capacitor is good 5 Repeat steps 3 and 4 to check fan motor capaci tor NOTE A shorted capacitor will indicate a low resis tance and the pointer will move to the 0 end of the scale and remain there as long as the probes are conn
19. ition you will get the most economi cal operation Both the fan and compressor will cycle on and off together maintaining the selected temperature at a more constant level and reducing the humidity more efficiently This control will only operate when the unit is in a cooling mode In the NO position the fan will run constantly as long as the unit is in the cooling mode TEST Disconnect leads from switch Depress switch to func tion being tested 1 When YES is depressed there should be continu ity between terminals 1 and 2 2 When NO is depressed there should be continu ity between terminals 2 and 3 FIGURE 11 ROCKER SWITCH BACK VIEW SEALED REFRIGERATION SYSTEM REPAIRS EQUIPMENT REQUIRED 1 2 Voltmeter Ammeter Ohmmeter E PA Approved Refrigerant Recovery System Vacuum Pump capable of 200 microns or less vacuum Acetylene Welder Electronic Halogen Leak Detector G E Type H 6 or equivalent Accurate refrigerant charge measuring device such as Page 12 9 10 11 a Balance Scales 1 2 oz accuracy b Charging Board 1 2 oz accuracy High Pressure Gauge 0 400 Ibs Low Pressure Gauge 30 150 Ibs Vacuum Gauge 0 1000 microns EQUIPMENT MUST BE CAPABLE OF 1 2 Recovering CFCs as low as 5 Evacuation from both the high side and low side of the system simultaneously Introducing refrigerant charge i
20. m CHASSIS PARTS Knob Control Panel Control Panel Control Bushing Snap 8 J 3 0 A E _ _ Enim ie je EHEN Gs ae sm ESE SER EEE EHEN E mua El 13 ER Hi 2 J 3 0 A EEE SERI if i L E EHE _1 ul at ul 11 tt SE ch 1111 Hi EE EI E k1 i at SEE B ma i at M E ER Em 1 1J1 a a Page 22 QUIETMASTER KS KM SERIES PARTS LIST PART NO DESCRIPTION APPLICATION REFRIGERATION SYSTEM COMPONENTS Cont DOVEN gt o x 618 027 00 Panel Assembly Left Side 618 042 00 Panel Assembly Left Side 618 028 00 Partition Control Box 618 043 00 Partition Control Box 618 204 00 Bracket Capacitor Mounting 618 207 00 Strap Capacitor 618 226 00 Decorative Panel 618 076 00 Grommet Suction Line 618 148 00 Connector Fresh Air amp Exhaust 618 172 00 Cover Top 618 167 00 Insulation Top Cover 618 168 00 Insulation Left Side Deck 618 171 00 608 658 08 Filter Air 608 658 09 Filter Air 618 230 00 Holder Filter 618 202 00 Air Foil 618 206 00 Bracket Resistor Block 915 003 01 Clamp Supply Cord 605 420 03 Fan Blade 605 420 04 Fan Blade 606 106 03 Blower Wheel 606 106 01 606 106 05 618 033 00 6
21. nnect vacuum pump to high side and low side of system with deep vacuum hoses or copper tubing Do not use regular hoses Evacuate system to maximum absolute holding pressure of 200 microns or less NOTE This pro cess can be speeded up by use of heat lamps or by breaking the vacuum with refrigerant or dry nitrogen at 5 000 microns Pressure system to 5 PSIG and leave in system a minimum of 10 min utes Recover refrigerant and proceed with evacu ation of a pressure of 200 microns or a minimum of 10 Break vacuum by charging system from the high side with the correct amount of refrigerant speci fied This will prevent boiling the oil out of the crank case NOTE Ifthe entire charge will not enter the high side allow the remainder to enter the low side in small increments while operating the unit Restart unit several times after allowing pressures to stabilize Pinch off process tubes cut and sol der the ends Remove pinch off tool and leak check the process tube ends SPECIAL PROCEDURE IN THE CASE OF MOTOR COMPRESSOR BURNOUT Recover all refrigerant and oil from the system Remove compressor capillary tube and filter drier from the system Flush evaporator condenser and all connecting tubing with dry nitrogen or equivalent to remove all contamination from system Inspect suction and discharge line for carbon deposits Remove and clean if necessary Reassemble the system including new drier strainer and cap
22. nting 618 207 00 Strap Capacitor 618 226 00 Decorative Panel 618 076 01 Grommet Suction Line 618 148 01 Connector Fresh Air amp Exhaust 618 179 00 Cover Top 618 182 00 Insulation Top Cover 618 183 00 Insulation Left Side Deck 618 180 00 608 658 10 Filter Air 618 230 00 Holder Filter 618 202 01 Air Foil 618 206 00 Bracket Resistor Block 915 003 01 Clamp Supply Cord 605 420 01 Fan Blade Not Shown Capillary length may vary flow rate is the same gt Page 27 PART NO QUIETMASTER KL SERIES PARTS LIST DESCRIPTION APPLICATION 606 106 02 618 066 00 618 067 00 618 077 00 618 100 00 618 169 02 618 178 00 618 181 00 618 215 00 318 071 01 618 074 00 618 188 02 01150934 914 004 00 618 105 00 618 093 00 618 096 00 618 097 00 618 097 01 618 092 00 618 257 02 618 084 01 618 104 00 618 199 00 602 944 10 611 050 03 611 095 03 618 197 03 618 198 05 606 103 03 608 460 16 617 173 01 618 116 05 618 140 00 618 141 00 618 118 02 618 196 00 600 733 00 PovwcurmrX CHASSIS PARTS Cont Brace Shroud Insulation Inner Wall Blower Front Scroll Door Slide Assembly Base Pan Drain Pan Grille Rear Grommet Compressor Bolt Compressor Mounting Plenum Assembly Knob Fresh Air amp Exhaust Connector Louver Louver Grille Louver with Handle Lever Fresh Air amp Exhaust Outer Shell with Sill Plate Sill Plate Grille Intake Latch Intake Grille
23. nto high side of the system Accurately weighing the refrigerant charge actually introduced into the system Facilities for flowing nitrogen through refrigeration tubing during all brazing processes HERMETIC COMPONENT REPLACEMENT The following procedure applies when replacing compo nents in the sealed refrigeration circuit or repairing re frigerant leaks Compressor condenser evaporator cap illary tube refrigerant leaks etc 1 Page 13 Recover the refrigerant from the system at the pro cess tube located on the high side of the system by installing a line tap on the process tube Apply gauge from process tube to EPA approved gauges from process tube to EPA approved recovery system Recover CFCs in system to at least 5 Cut the process tube below pinch off on the suc tion side of the compressor Connect the line from the nitrogen tank to the suc tion process tube Drift dry nitrogen through the system and unsolder the more distant connection first Filter drier high side process tube etc Replace inoperative component and always install a new filter drier Drift dry nitrogen through the sys tem when making these connections Pressurize system to 30 PSIG with proper refriger ant and boost refrigerant pressure to 150 PSIG with dry nitrogen 10 11 12 Leak test complete system with electric halogen leak detector correcting any leaks found Reduce the system to zero gauge pressure Co
24. ompressor running abnormally Check for kinked discharge line or restricted condenser hot Check amperage PROBLEM POSSIBLE CAUSE TO CORRECT Loss of charge in thermostat Place jumper across thermostat terminals to check if unit bulb operates If unit operates replace the thermostat Loose or broken parts in thermo Check as above Thermostat does not stat turn unit on Incorrect wiring Refer to appropriate wiring diagram PROBLEM POSSIBLE CAUSE TO CORRECT Poorly installed unit Refer to Installation Instructions for proper installation Noi Fan blade striking chassis Reposition adjust motor mount olsy operation Check that compressor grommets have not deteriorated Improperly mounted or loose Check that compressor mounting parts are not missing cabinet parts PROBLEM POSSIBLE CAUSE TO CORRECT Evaporator drain pan overflow Clean obstructed drain trough ing room pan Poor installation resulting in rain Check installation instructions Reseal as required Fu Dirty evaporator coil clean Very high humidity level grilles Page 17 PROBLEM POSSIBLE CAUSE TO CORRECT Thermostat differential too Replace thermostat narrow Plenum gasket not sealing Check gasket reposition or replace Thermostat short allowing discharge air to short cycles cycle the thermostat thermostat bulb support bracket Applicable models PROBLEM POSSIBLE CAUSE TO CORRECT Anticipato
25. ory Package Accessory Package Bracket Support Angle Wingboard Top Angle Wingboard Side Angle Wingboard Side Gasket Vinyl Plastic Bag Hardware Gasket Chassis Foam Carton Shipping Carton Shipping Pad Shipping Pad Shipping Pad Shipping Pad Shipping Top Gasket Window Foam OPTIONAL ACCESSORIES Drain Condensate Connection Kit DC 2 Start Kit Capacitor Relay Pow R Pak O CC lt n N lt x O uJ O a x CC ui O lt F u lt Page 25 QUIETMASTER KL SERIES PARTS LIST PART NO DESCRIPTION APPLICATION PovwcurmrX ELECTRICAL PARTS 615 935 47 Compressor Tecumseh 230 208 V 60 Hz 1 Ph Model AWR5524EXN 610 714 85 Motor Fan 605 000 49 Cord Electric Supply 20 Amp 250 Volt 606 072 03 System Switch 618 061 00 Rocker Switch 618 225 00 Thermostat 610 803 34 Capacitor Run 35 7 5 MFD 370 V 618 211 00 Harness Wire Compressor 618 208 00 Harness Wire Fan Motor 618 080 01 Resistor Block 230 V NOD GI PUN 618 501 02 Coil Evaporator 618 503 07 Coil Condenser 03760548 Capillary Tube 054 I D X 37 1 4 40 Long 614 831 00 Filter Drier use when repairing sealed system 614 939 05 Knob Control 618 069 00 Panel Control 600 713 12 Bushing Snap 618 068 00 Panel Left Side 618 176 00 Insulation Left Side 618 070 00 Partition Control Box 618 204 00 Bracket Capacitor Mou
26. ows 1 Install a piercing valve on the suction and dis charge or liquid process tube 2 Attach gauges to the high and low sides of the system 3 Start the system and run a cooling or heating performance test If test shows A Below normal high side pressure B Above normal low side pressure C Low temperature difference across coil The compressor valves are faulty replace the compressor THERMAL OVERLOAD External Some compressors are equipped with an external over load which is located in the compressor terminal box adjacent to the compressor body see Figure 3 The overload is wired in series with the common motor terminal The overload senses both major amperage and compressor temperature High motor temperature or amperage heats the disc causing it to open and break the circuit to the common motor terminal Figure 3 External Overload OVERLOAD Heat generated within the compressor shell is usually due to 1 High amperage 2 Lowrefrigerant charge 3 Frequent recycling 4 Dirty condenser THERMAL OVERLOAD TEST Compressor External Type 1 Remove overload 2 Allow time for overload to reset before attempting to test 3 Apply ohmmeter probes to terminals on overload wires There should be continuity through the over load TERMINAL OVERLOAD Internal Some model compressors are equipped with an inter nal overload The overload is embedded in the motor windings to sense t
27. r resistor wire Refer to appropriate wiring diagram disconnected at thermostat or Prolonged off cycles system switch mem En va u i open Applicable models Partial loss of charge inthermo Replace thermostat ential PROBLEM POSSIBLE CAUSE TO CORRECT Switches from cooling _Thermostat sticking Change room thermostat to heating Incorrect wiring Refer to appropriate wiring diagram PROBLEM POSSIBLE CAUSE TO CORRECT Evaporator drain pan cracked or Repair clean or replace as required obstructed Outside water leaks Water in compressor area Detach shroud from pan and coil Clean and remove old sealer Reseal reinstall and check Fan blade and slinger ring Adjust fan blade 3 16 to 1 4 from condenser shroud Adjust fan motor mount to allow 3 16 to 1 4 clearance between condenser fan blade and base pan PROBLEM POSSIBLE CAUSE TO CORRECT Insufficient air circulation in air Adjust louvers for best possible air circulation conditioned area High indoor humidity Operate in Fan Auto Moneysaver position Inadequate vapor barrier in Advise customer building structure particularly floors Page 18 COMPRESSOR WIRING DIAGRAM C S R ORIENTATION MAY VARY DEPENDING UPON MANUFACTURER RED BLACK ALTERNATE COMPRESSOR OVERLOAD PROTECTOR COMPRESSOR WIRE HARNESS ORANGE SEE WIRE COLOR NOTE ANTICIPATOR RESISTOR CAPACITOR SMOOTH CONDUCTOR OR BROWN SUPPLY CO
28. s for light and electrical equipment except the air conditioner itself that will be in use when the room air conditioning is operating Multiply the total wattage by the factor given 8 Multiply the total width linear feet of any doors or arches which are continually open to an unconditioned space by the applicable factor NOTE Where the width of the doors or arches is more than 5 feet the actual load may exceed the calculated value In such cases both adjoining rooms should be considered as a single large room and the room air conditioner unit or units should be selected according to a calculation made on this new basis 9 Total the loads estimated for the foregoing 8 items 10 Multiply the subtotal obtained in item 9 by the proper correction factor selected from the map for the particular locality The result is the total estimated design cooling load in BTU per hour E For best results a room air conditioner unit or units having a cooling capacity rating determined in accordance with the NEMA Standards Publication for Room Air Conditioners CN 1 1960 as close as possible to the esti mated load should be selected In general a greatly oversized unit which would operate intermittently will be much less satisfactory than one which is slightly undersized and which would operate more nearly continuously F Intermittent loads such as kitchen and laundry equipment are not included in this form Page 6 COOLING LOAD ESTIMATE FORM HEA
29. sq ft sq ft sq ft sq ft Item 9 x Light Construction 30 60 Factor from Map _ ROCHESTER _ ALBANY Lf NEW HAVEN COLUMBIA ATLANTA SPECIFICATIONS BTUH Volts Amperes Total Watts Fuse Breaker Size Evaporator Air CFM Fresh Air CFM Exhaust Air CFM Dehumidification Pts HR Minimum Ext Into Room Minimum Ext to Outside Shipping Weight PERFORMANCE EVAPORATOR AIR OPERATING ELECTRICAL DATA TEMP F PRESSURES RATINGS OIL DISCHARGE TEMP SUCTION DISCHARGE AIR DROP F o I 118 00 Cooling KS10J10 KS12J10 KS12J30A KM18J30A KM21J30 KL25J30A Rating Conditions 32 0 80 F Room Air Temperature and 50 Relative Humidity with KS10J10 KS12J10 KS12J30A KM18J30A KM21J30 KL25J30A 12500 18000 21000 25000 12000 12500 18000 20500 24700 10 0 9 6 9 0 8 3 9 5 10 0 9 6 9 0 8 2 230 230 230 230 115 208 208 208 208 5 8 3 10 5 13 5 8 6 9 1 11 3 15 0 1875 2335 3010 1250 1250 1875 2280 3010 1180 1120 1120 8 2 25 s s 5 1 1265 O 1080 1120 0 15 325 610 Yes Yes Yes Yes 3 5 7 6 2 8 x 25 15 16 15 15 16 27 3 8 EE a 3 Ye Ye E 28 20 3 16 33 5 8 3 3 16 18 15 16 COMP CHARGE IN FLUID OZ LOCKED CHARGE IN ROTOR AMPS 02 9 1 11 8 11 8 13 9 32 0 95 F Outside Air Temperature at 40 Relative Humidity Page 7 COMPONENTS OPERATION amp TESTING WARNING DISCO
30. y a small amount of heat to the bulb area to prevent long off cycles in the Cool Fan Auto Money Saver position see Figure 10 A current feedback through the fan motor windings during off cycle com pletes the circuit to the resistor RANGE Cooling Model Thermostat Part No 618 225 00 60 F 2 to 92 4 TEST Remove wires from thermostat Turn the thermostat to its coldest position Check to see if there is continuity between the two terminals Turn the thermostat to its warmest position Check continuity to see if thermostat contacts open NOTE Temperature must be within range listed to check thermostat Refer to the troubleshooting section in this manual for additional information on ther mostat testing THERMOSTAT ADJUSTMENT No attempt should be made to adjust thermostat Due to the sensitivity of the internal mechanism and the so phisticated equipment required to check the calibration it is suggested that the thermostat be replaced rather than calibrated Page 11 RESISTOR Heat Anticipator Failure of the resistor will cause prolonged off and on cycles of the unit When replacing a resistor be sure and use the exact replacement Resistor ratings are as follows 115 Volt 5 000 ohms 3 watt 230 Volt 20 000 ohms 3 watt Figure 10 RESISTOR MONEYSAVER SWITCH Rocker Switch See Figure 11 This rocker switch can be depressed to either YES or NO In the YES pos
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