Daikin DP14UM Operating instructions
RSD6313002
October 2021
This manual is to be used by qualied, professionally trained HVAC technicians only.
Daikin does not assume any responsibility for property damage or personal injury due to
improper service procedures or services performed by an unqualied person.
Copyright © 2021
TABLE OF CONTENTS
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2
IMPORTANT INFORMATION
While these items will not cover every concievable
situaon, they should serve as a usefull guide.
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OUTSIDE THE U.S., .
(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.
3
PRODUCT IDENTIFICATION
The model number is used for posive idencaon of component parts used in manufacturing. Please use this number
when requesng service or parts informaon.
060
080
60,000 BTU/H
80,000 BTU/H
24 - 2 tons
30 - 2½ tons
36 - 3 tons
14 - 14 SEERR
D P 14 U M 24 060 4 1 A A
1 2 3,4 5 6 7,8 9,10,11 12 13 14 15
Engineering
Brand Minor revision
D - Daikin Engineering
Major revision
Product Type Voltage
P - Packaged 1 - 208/230V single-phase, 60 Hz
SEER Refrigerant
4 - R-410A
Nominal Heat Input
Unit Type
Tonnage Nominal
040 40,000 BTU/H
16- 16SEERR
42 - 2½ tons
48 - 3 tons
61 - 5 tons
U - Ultra Low/NOx
<= 14 ng/J
4
PRODUCT IDENTIFICATION
These units have R410A refrigerant
Model # Description
DP14UM[24-48]***41AA
Daikin Brand Ultra-Low Nox Package Gas 14 Seer R410A Multi-Position gas/electric units.
Initial release of single phase models.
DP16UM[30-36]***41AA
Daikin Brand Ultra-Low Nox Package Gas 16 Seer R410A Multi-Position gas/electric units.
Initial release of single phase models.
Single Phase Package Gas Units
5
SYSTEM OPERATION
The refrigerant used in the system is R-410A. It is a clear,
colorless, non-toxic and non-irritang liquid. R-410A is a
50:50 blend of R-32 and R-125. The boiling point at atmo-
spheric pressure is -62.9°F.
A few of the important principles that make the
refrigeraon cycle possible are: heat always ows 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 o and condensed
at a higher pressure and temperature to be used again.
The indoor evaporator coil funcons to cool and
dehumidify the air condioned spaces through the
evaporave process taking place within the coil tubes.
Liquid refrigerant at condensing pressure and
temperatures, (270 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 poron of the liquid immediately vaporizes.
It connues to soak up heat and vaporizes as it proceeds
through the coil, cooling the indoor coil down to about
48°F.
Heat is connually being transferred to the cool ns 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 o by the vapor.
As the vapor passes through the last tubes of the coil, it
becomes superheated. That is, it absorbs 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, rst loses its superheat by
heat transferred from the gas through the tubes and ns
of the coil. The refrigerant now becomes saturated, part
liquid, part vapor and then connues to give up heat unl
it condenses to a liquid alone. Once the vapor is fully
liqueed, it connues to give up heat which subcools the
liquid, and it is ready to repeat the cycle.
The heang cycle is accomplished by using a unique
tubular design heat exchanger which provides ecient gas
heang on natural gas fuel. The heat exchanger’s compact
tubular construcon provides excellent heat transfer for
maximum operang eciency.
The induced dra blower draws fuel and combuson air
into the burner and through the heat exchanger for proper
combuson.
Blower operaon is controlled by the integrated control
module. The module allows for eld adjustment of the
blower delay at the end of the heang cycle. The range
of adjustment is 90, 120, 150 or 180 seconds. The factory
delay sengs are 30 seconds delay on, 150 seconds delay
o.
DP14UM/DP16UM units are equipped with a direct spark
ignion system. Ignion is provided by a 25,000 volt
electronic spark. A ame sensor then monitors for the
presence of ame and closes the gas valve if ame is lost.
1. When the thermostat calls for connuous fan (G) with
out a call for heat or cooling, the indoor the fan has
a 7 second delay on make and energizes the “HEAT”
speed. The fan remains energized as long as the call
for fan remains without a call for heat or cooling. The
fan call “G” has a 60 second delay on break. Note:
When the Conguraon tab is broken, the connuous
fan mode “G” will have a 7 second delay on make and
a 60 second delay on break and the “COOL” speed tap
will be energized.
2. If a call for cool (Y) occurs during connuous fan, the
blower will switch over to “COOL” speed.
3. If a call for heat (W) occurs during connuous fan, the
blower will remain energized through the heat cycle
or unl “G” is de-energized.
6
SYSTEM OPERATION
4. The connuous fan operaon will funcon while the
control is in heat mode lockout.
1. When the thermostat calls for cooling (“Y”), the
control energizes the cooling speed fan aer a 7
second on delay. The control provides a 3 minute
an-short cycle protecon for the compressor. If
the compressor has been o for 3 or more minutes,
the compressor immediately energizes when the
thermostat calls for cool. If the compressor has not
been o for at least 3 minutes when a call for cool
occurs, the control waits unl 3 minutes has elapsed
from the me the compressor was last de-energized
before re-energizing the compressor.
2. When the thermostat removes the call for cooling
(“Y”) the compressor is deenergized and the control
deenergizes the cooling speed fan aer a cooling o
delay period of 60 seconds.
The normal operaonal sequence in heang mode is as
follows:
• R and W thermostat contacts close, iniang a call for
heat.
• Integrated control module performs safety circuit
checks.
• Pressure Sensor Vericaon: The control operates the
inducer in a manner to verify the pressure sensor null
value and span operaon are within specicaon. If
the system is operang correctly, this test takes only a
few seconds. If the system is not funconing properly,
the control mes out aer a maximum 90 seconds and
displays the proper fault code.
• Induced dra blower is energized for 30 second
prepurge.
• The control energizes the gas valve and spark igniter. If
ame is not established within 4 seconds, the gas valve
and spark igniter is de-energized and the control goes
to an inter-purge. If the ame is established, the spark
igniter is de-energized and the control goes to heat
blower on delay.
• Heat Blower On Delay – The control waits for 30 second
heat fan on delay and then energizes the indoor blower
heat speed. If the blower is already energized by a
connuous fan call, the on delay is skipped and control
goes to heat fan speed.
• STEADY HEAT – Control inputs are connuously
monitored for ensure limit and pressure switches are
closed, ame is established and the thermostat call for
heat remains.
• POST PURGE – When the thermostat demand for heat
is sased, the control immediately de-energizes the
gas valve. The inducer output remains on for a 30
second post-purge period.
• Heat Blower O Delay – The indoor blower motor is
de-energized aer the selected blower o delay me.
Blower ming begins when the thermostat is sased.
7
SYSTEM OPERATION
LED
ACTIVITY
DESCRIPTION COLOR
MINIMUM
LOCKOUT PERIOD
LED OFF
NO 24 VAC POWER
TO CONTROL
N/A N/A
RED,
AMBER,
GREEN
POWER-UP
VERIFICATION OF
LED
N/A N/A
STEADY ON
CONTROL FAULT
DETECTED
RED
1 HOUR OR
HARD LOCKOUT
1 FLASH RETRIES EXCEEDED RED 1 HOUR FIXED
2 FLASHES
PRESSURE SENSOR
NULL ERROR
RED 5 MINUTES
3 FLASHES
PRESSURE SENSOR
SPAN ERROR
RED 5 MINUTES
4 FLASHES
HIGH LIMIT
SWITCH OPEN
RED
MAXIMUM
RECOVERY TIME
1 HOUR AFTER
MAX TRIPS
EXCEEDED
5 FLASHES
FLAME PRESENT
WITH GAS VALVE
OFF
RED 5 MINUTES
6 FLASHES
NORMALLY CLOSED
BLOCKED BURNER
SWITCH / AUXILIARY
SWITCH OPEN
RED
MAXIMUM
RECOVERY TIME
1 HOUR IF TIME
EXCEEDED
7 FLASHES
GAS VALVE CIRCUIT
SHORTED
RED 1 HOUR
8 FLASHES RESERVED RED N/A
10
FLASHES
HIGH LIMIT SWITCH
RECOVERY TIMER
EXPIRED
RED
1 HOUR OR
HARD LOCKOUT
STEADY ON
OEM FACTORY TEST
MODE
AMBER N/A
RAPID
FLASH
FIELD TEST MODE AMBER N/A
1 FLASH LOW FLAME SENSE AMBER N/A
2 FLASHES ID PLUG FAILURE AMBER
HARD LOCKOUT
HEATING MODE
3 FLASHES
CONTROL FUSE
OPEN
AMBER 5 MINUTES
STEADY ON
STANDBY NORMAL
OPERATION NO
THERMOSTAT CALL
GREEN N/A
RAPID
FLASH
CLEAR ERROR
HISTORY
GREEN N/A
1 FLASH CALL FOR
HEATING GREEN N/A
2 FLASHES CALL FOR
COOLING GREEN N/A
3 FLASHES
CONTINUOUS
FAN OPERATION
GREEN N/A
PCBBL216 ULN CONTROL ERROR CODES
Each 80% ULN model has a unique ID Plug that needs to
be installed into the board for your specic model number.
The ID Plug will populate the board with the correct
operang parameters for each model and should be le on
the board once installed.
Please see the table below for reference:
0130G00012 DP**UM**04041AA
0130G00013 DP**UM**06041AA
0130G00014 DP**UM**08041AA
8
SYSTEM OPERATION
The following procedure will ensure the proper operang
parameters are installed onto the board. Each model has a
unique ID PLUG that needs to be installed onto the board.
Please see the instrucons below:
1. Select the appropriate ID plug for the installed model
number from the table above.
2. Aached the appropriate ID plug for the installed
model number to the control board into the blue
connector as shown below. This will load the correct
parameters to the board. Failure to follow these
instrucons will result in the board not funconing.
9
SYSTEM OPERATION
Either a thermostac expansion valve or restrictor orice assembly may be used depending on model, refer to the parts
catalog for the model being serviced.
In the cooling mode, the orice is pushed into its seat forcing refrigerant to ow through the metered hole in the center
of the orice.
10
SERVICING
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11
SERVICING
1. Remove doors, control panel cover, etc. from unit
being tested.
With power ON:
2. Using a voltmeter, measure the voltage across
terminals L1 and L2 of the contactor for single phase
units, and L3, for 3 phase units.
3. No reading - indicates open wiring, open fuse(s) no
power or etc. from unit to fused disconnect service.
Repair as needed.
4. If incoming voltage is within the range listed in the
chart below, energize the unit.
5. Using a voltmeter, measure the voltage with the
unit starng and operang to determine if voltage is
within the range listed in the chart below.
6. If the voltage falls below the minimum voltage, check
the line wire size. Long runs of undersized wire can
cause low voltage. If the wire size is adequate, nofy
the local power company regarding either low or high
voltage.
208/230 198 253
1. Check wiring visually for signs of overheang,
damaged insulaon and loose connecons.
2. Use an ohmmeter to check connuity of any
suspected open wires.
3. If any wires must be replaced, replace with
comparable gauge and insulaon thickness.
Thermostat Wiring: The maximum wire length for 18 AWG
thermostat wire is 100 feet.
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.
2. No voltage indicates trouble in the thermostat, wiring
or external transformer source.
3. Check the connuity of the thermostat and wiring.
Repair or replace as necessary.
With power ON:
1. Set fan selector switch at thermostat to “ON”
posion.
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 connuity of the thermostat and wiring.
Repair or replace as necessary.
12
SERVICING
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
outdoor secons do not contain a transformer.
1. Remove control panel cover, or etc., to gain access to
transformer.
With power ON:
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 connecons and/or splices.
5. If line voltage available at primary voltage side of
transformer and wiring and splices good, transformer
is inoperave. Replace.
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 is de-energized, springs return the contacts
to their normal posion.
1. Remove the leads from the holding coil.
2. Using an ohmmeter, test across the coil terminals.
If the coil does not test connuous, replace the relay or
contactor.
1. Disconnect the wire leads from the terminal (T) side
of the contactor.
2. With power ON, energize the contactor.
3. Using a voltmeter, test across terminals.
A. L1 - L2 - No voltage. Check breaker or fuses on
main power supply.
B. L2 - T1 - No voltage indicates CC1 contacts
open.
If a no voltage reading is obtained - replace the contactor.
13
SERVICING
The fan relays are incorporated into the control board. See
Tesng Ignion Control Module for checking control board.
The high pressure control senses the pressure in the liquid
line. If abnormally high condensing pressures develop, the
contacts of the control open, breaking the control circuit
before the compressor motor overloads. This control is
automacally reset.
1. Using an ohmmeter, check across terminals of
high pressure control, with wire removed. If not
connuous, the contacts are open.
2. Aach a gauge to the dill valve port on the base valve.
With power ON:
3. Start the system and place a piece of cardboard in
front of the condenser coil, raising the condensing
pressure.
4. Check pressure at which the high pressure control
cuts-out.
If it cuts-out at 660 PSIG ± 10 PSIG, it is operang normally.
If it cuts out below this pressure range, replace the control.
The control should reset at 420 PSIG ± 25 PSIG.
The low pressure control senses the pressure in the sucon
line and will open its contacts on a drop in pressure. The
low pressure control will automacally reset itself with a
rise in pressure.
The low pressure control is designed to cut-out (open) at
approximately 55 PSIG ± 7 PSIG. It will automacally cut-in
(close) at approximately 95 PSIG ± 7 PSIG.
Test for connuity using a VOM and if not as above,
replace the control.
A run capacitor is wired across the auxiliary and main
windings of a single phase permanent split capacitor
motor. The capacitors primary funcon is to reduce
the line current while greatly improving the torque
characteriscs of a motor. This is accomplished by using
the 90° phase relaonship between the capacitor current
and voltage in conjuncon with the motor windings so that
the motor will give two phase operaon when connected
to a single phase circuit. The capacitor also reduces the
line current to the motor by improving the power factor.
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 hard start kits are available and may improve low
voltage starng characteriscs.
This check valve closes o high side pressure to the
compressor aer shut down allowing equalizaon through
the scroll anks. Equalizaon requires only about one or
two seconds during which me the compressor may turn
backwards.
Your unit comes with a 180-second an-short cycle
to prevent the compressor from starng and running
backwards.
A start capacitor is wired in parallel with the run capacitor
to increase the starng torque. The start capacitor is of
the electrolyc type, rather than metallized polypropylene
as used in the run capacitor.
A switching device must be wired in series with the
capacitor to remove it from the electrical circuit aer the
compressor starts to run. Not removing the start capacitor
will overheat the capacitor and burn out the compressor
windings.
These capacitors have a 15,000 ohm, 2 wa resistor
wired across its terminals. The object of the resistor
is to discharge the capacitor under certain operang
condions, rather than having it discharge across the
closing of the contacts within the switching device such as
the Start Relay, and to reduce the chance of shock to the
servicer. See the Servicing Secon for specic informaon
concerning capacitors.
14
SERVICING
A potenal 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 posion sensive. 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.
Two quick ways to test a capacitor are a resistance and a
capacitance check.
1. Discharge capacitor and remove wire leads.
2. Set an ohmmeter on its highest ohm scale and
connect the leads to the capacitor -
A. Good Condion - indicator swings to zero and
slowly returns to innity. (Start capacitor with
bleed resistor will not return to innity. It will
sll read the resistance of the resistor).
B. Shorted - indicator swings to zero and stops
there -replace.
C. Open - no reading - replace. (Start capacitor
would read resistor resistance.)
Using a hookup as shown below, take the amperage and
voltage readings and use them in the formula:
Capacitance (MFD) = 2650 X Amperage
Voltage
The auto reset fan motor overload is designed to protect
the motor against high temperature and high amperage
condions 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.
15
SERVICING
1. Remove the motor leads from its respecve
connecon points and capacitor (if applicable).
2. Check the connuity 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 connuous or a reading is
obtained from lead to ground, replace the motor.
1. Disconnect the 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
connuity to ground (pins to motor shell). If the
ohmmeter indicates connuity to ground, the motor
is defecve and must be replaced.
5. Using an ohmmeter, check the windings for connuity
(pin to pin). If no connuity is indicated, the thermal
limit (over load) device may be open. Allow motor to
cool and retest.
Motor
Connector
(3-pin)
Motor OK when
R > 100k ohm
(3-pin)
The EEM motor is a one piece, fully encapsulated, 3 phase
brushless DC (single phase AC input) motor with ball
bearing construcon. The EEM motor features an integral
control module.
1. Using a voltmeter, check for 230 volts to the motor
connecons L and N. If 230 volts is present, proceed
to step 2. If 230 volts is not present, check the line
voltage circuit to the motor.
2. Using a voltmeter, check for 24 volts from terminal C
to either terminal 1, 2, 3, 4, or 5, depending on which
tap is being used, at the motor. If voltage present,
proceed to step 3. If no voltage, check 24 volt circuit
to motor.
3. If voltage was present in steps 1 and 2, the motor has
failed and will need to be replaced.
16
SERVICING
CL G N
1 2 3 45
High Voltage
Connections
3/16"
Low Voltage Connections
1/4”
An ECM is an Electronically Commutated Motor which
oers many signicant advantages over PSC motors.
The ECM has near zero rotor loss, synchronous machine
operaon, variable speed, low noise, and programmable
air ow. Because of the sophiscated electronics within
the ECM motor, some technicians are inmated by the
ECM motor; however, these fears are unfounded. GE/
Regal Beloit oers two ECM motor testers, and with a VOM
meter, one can easily perform basic troubleshoong on
ECM motors. An ECM motor requires power (line voltage)
and a signal (24 volts) to operate. The ECM motor stator
contains permanent magnet. As a result, the sha feels
“rough” when turned by hand. This is a characterisc of
the motor, not an indicaon of defecve bearings.
1. Disconnect the 5-pin connector from the motor.
2. Using a volt meter, check for line voltage at terminals
#4 & #5 at the power connector. If no voltage is
present:
3. Check the unit for incoming power.
4. Check the control board.
5. If line voltage 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 to the
“G” terminal at the 16-pin connector.
8. Using an ohmmeter, check for connuity from the #1
& #3 (common pins) to the transformer neutral or “C”
thermostat terminal. If you do not have connuity,
the motor may funcon erracally. Trace the common
circuits, locate and repair the open neutral.
9. Set the thermostat to “Fan-On”. Using a voltmeter,
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 heang. Using a
voltmeter, check for 24 volts at pin #2 and/or #11.
1
2
3
4
5
Lines 1 and 2 will be connected
for 12OVAC Power Connector
applications only
Gnd
AC Line Connection
AC Line Connection
}
11
1 9
2
3
4
5
6
7
8 16
15
14
13
12
10
OUT - OUT +
ADJUST +/- G (FAN)
Y1 Y/Y2
COOL EM Ht/W2
DELAY 24 Vac (R)
COMMON2 HEAT
W/W1 BK/PWM (SPEED)
COMMON1 O (REV VALVE)
16-PIN ECM HARNESS CONNECTOR
If you do not read voltage and connuity 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 defecve and must be replaced.
17
SERVICING
1. Disconnect the 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
connuity to ground (pins to motor shell). If the
ohmmeter indicates connuity to ground, the motor
is defecve and must be replaced.
5. Using an ohmmeter, check the windings for connuity
(pin to pin). If no connuity is indicated, the thermal
limit (over load) device may be open. Allow motor to
cool and retest.
16-pin
connector
5-pin
connector
3-pin motor
connector
If the compressor terminal PROTECTIVE COVER and 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, spoung ames
several feet, causing potenally 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
discharge impinges on a sucient heat source.
Ignion of the discharge can also occur at the venng
terminal or inside the compressor, if there is sucient
contaminant air present in the system and an electrical arc
occurs as the terminal vents.
Ignion cannot occur at the venng terminal without the
presence of contaminant air, and cannot occur externally
from the venng terminal without the presence of an
external ignion source.
Therefore, proper evacuaon of a hermec system is
essenal at the me of manufacture and during servicing.
To reduce the possibility of external ignion, all open
ame, electrical power, and other heat sources should be
exnguished or turned o prior to servicing a system.
Each compressor is equipped with an internal overload.
The line break internal overload senses both motor
amperage 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 insucient 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 protecve device, etc.
has not tripped -
1. Remove the leads from the compressor terminals.
18
SERVICING
2. Using an ohmmeter, test connuity between
terminals S-R, C-R, and C-S, on single phase units or
terminals T1, T2 and T3, on 3 phase units.
If either winding does not test connuous, replace the
compressor.
If fuse, circuit breaker, ground fault protecve device, etc.
has tripped, this is a strong indicaon that an electrical
problem exists and must be found and corrected. The
circuit protecve device rang must be checked and its
maximum rang should coincide with that marked on the
equipment nameplate.
With the terminal protecve cover in place, it is acceptable
to replace the fuse or reset the circuit breaker
to see if it was just a nuisance opening. If it opens
again, connue to reset.
all
1. Carefully remove the compressor terminal protecve
cover and inspect for loose leads or insulaon breaks
in the lead wires.
2. Disconnect the three leads going to the compressor
terminals at the compressor or nearest point to the
compressor.
3. Check for a ground separately between each of the
three terminals and ground (such as an unpainted
tube on the compressor). If there is any reading of
connuity to ground on the meter, the compressor
should be considered defecve.
4. If ground is indicated, replace the compressor.
A nominal 24-volt direct current coil acvates the
compressor internal unloader solenoid. The input control
circuit voltage must be 18 to 28 volt ac. (remove) The
coil power requirement is 5 VA . The external electrical
connecon is made with a molded plug assembly. This plug
contains a full wave recer to supply direct current to the
unloader coil. The measured DC voltage at the connectors
in the plug should be 15 to 27 volt dc.
19
SERVICING
If it is suspected that the unloader is not working, the
following methods may be used to verify operaon.
1. Operate the system and measure compressor
amperage. Cycle the unloader ON and OFF at 10
second intervals. The compressor amperage should
increase when switching from part-load to full-load
and decrease when switching from full-load to part-
load. The percent change depends on the operang
condions and voltage, but should be at least 25
percent.
2. If step one does not give the expected results, shut
unit o. Apply 18 to 28 volt ac to the unloader molded
plug leads and listen for a click as the solenoid pulls
in. Remove power and listen for another click as the
unloader returns to its original posion.
3. If clicks can’t be heard, shut o power to the unit
and remove the control circuit molded plug from the
compressor and measure the unloader coil resistance
(connecons on the compressor). The solenoid coil
should have connuity and not be grounded or have
innite resistance. If the coil resistance is innite,
zero, or grounded, the compressor must be replaced.
4. Next check the molded plug.
A. Voltage check: Apply control voltage to the plug
wires (18 to 28 volt ac). The measured dc voltage
at the female connectors in the plug should be
around 15 to 27 vdc.
B. Resistance check: Measure the resistance from
the end of one molded plug lead to either of the
two female connectors in the plug. One of the
connectors should read close to zero ohms while
the other should read innity. Repeat with other
wire. The same female connector as before
should read zero while the other connector again
reads innity. Reverse polarity on the ohmmeter
leads and repeat. The female connector that
read innity previously should now read close to
zero ohms.
C. Replace plug if either of these test methods
doesn’t show the desired results.
If the voltage, capacitor, overload and motor winding test
fail to show the cause for failure:
1. Remove unit wiring from disconnect switch and wire
a test cord to the disconnect switch.
2. With the protecve terminal cover in place, use the
three leads to the compressor terminals that were
disconnected at the nearest point to the compressor
and connect the common, start and run clips to the
respecve leads.
3. Connect good capacitors of the right MFD and voltage
rang into the circuit as shown.
4. With power ON, close the switch.
A. If the compressor starts and connues to run, the
cause for failure is somewhere else in the sys-
tem.
B. If the compressor fails to start - replace.
If fuse, circuit breaker, ground fault protecve device, etc.
has tripped, this is a strong indicaon that an electrical
problem exists and must be found and corrected. The
circuit protecve device rang must be checked and its
maximum rang should coincide with that marked on the
equipment nameplate.
Before checking for locked rotor, the compressor terminals
should be checked for open windings (see Resistance Test)
and the run capacitor and start capacitor (if used) should
be checked thoroughly (see Checking Capacitor).
20
SERVICING
With power ON:
1. Check the serial data plate for the compressor locked
rotor amps (LRA) rang.
2. Using an ampmeter, measure the amperage reading
for the run and common wires to the compressor.
Since the compressor motor overload will likely
trip soon aer drawing locked rotor amps, this
measurement should be taken as soon as the
compressor starts.
3. If the amperage reading roughly equals the
compressor LRA rang and all other checks have been
completed, locked rotor amps has been veried.
The crankcase heater must be energized a minimum of
four (4) hours before the condensing unit is operated.
Crankcase heaters are used to prevent migraon or
accumulaon of refrigerant in the compressor crankcase
during the o cycles and prevents liquid slugging or oil
pumping on start up.
A crankcase heater will not prevent compressor damage
due to a oodback or over charge condion.
1. Disconnect the heater lead in wires.
2. Using an ohmmeter, check heater connuity - should
test connuous. If not, replace.
When repairing the refrigeraon system:
1. Never open a system that is under vacuum. Air and
moisture will be drawn in.
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 ow well on oxidized or oily surfaces.
4. Clean the inside of all new tubing to remove oils and
pipe chips.
5. When brazing, sweep the tubing with dry nitrogen
to prevent the formaon of oxides on the inside
surfaces.
6. Complete any repair by replacing the liquid line drier
in the system, evacuate and charge.
- Sil-Fos used without ux
(alloy of 15% silver, 80% copper, and 5% phosphorous).
Recommended heat 1400°F.
- Silver Solder used without a ux
(alloy of 30% silver, 38% copper, 32% zinc). Recommended
heat - 1200°F.
–
ZA-1 Brazing Rods use Flux System Cesium-Based Polymer
System (alloy of 78% Zinc and 22% Aluminum). Melng
point 826*F Flow point 905*F.
Pressure test the system using dry nitrogen and soapy
water to locate leaks. If you wish to use a leak detector,
charge the system to 10 psi using the appropriate
refrigerant then use nitrogen to nish charging the system
to working pressure, then apply the detector to suspect
areas. If leaks are found, repair them. Aer repair, repeat
the pressure test. If no leaks exist, proceed to system
evacuaon.
This manual suits for next models
1
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