Friedrich Hazardgard SH15M30 User manual

R-410A Models
Service Manual
2 0 1 1
HG-ServMan (1-11)
SH15M30*
SH20M30*
Cool Only
Hazardous Duty
Room Air Conditioner
*Last character may vary.

Table Of Contents
Important Safety Information ..................................................................................................................... 2-4
Introduction ................................................................................................................................................... 4
Unit Identification .......................................................................................................................................... 5
Hazardgard Application ................................................................................................................................ 6
Performance Specifications and Installation Data ........................................................................................ 7
Electrical Data .............................................................................................................................................. 8
Hazardgard Special Features ...................................................................................................................... 9
Component Definitions ............................................................................................................................... 10
Component Testing ................................................................................................................................ 11-12
R-410A Sealed System Repair Considerations .......................................................................................... 13
Sealed Refrigeration System Repairs ................................................................................................... 14-17
Refrigerant Charging ............................................................................................................................. 14-17
Compressor Checks .............................................................................................................................. 18-19
Compressor Replacement ..................................................................................................................... 19-20
Routine Maintenance ............................................................................................................................. 21-22
Performance Test Data Sheet ..................................................................................................................... 23
Troubleshooting ..................................................................................................................................... 24-26
Wiring Diagram and Schematic .................................................................................................................. 27
Warranty ..................................................................................................................................................... 28
Technical Assistance ................................................................................................................................... 29
1

IMPORTANT SAFETY INFORMATION
The information contained in this manual is intended for use by a qualified service technician who is familiar
with the safety procedures required for installation and repair, and who is equipped with the proper tools and
test instruments required to service this product.
Installation or repairs made by unqualified persons can result in subjecting the unqualified person making
such repairs as well as the persons being served by the equipment to hazards resulting in injury or electrical
shock which can be serious or even fatal.
Safety warnings have been placed throughout this manual to alert you to potential hazards that may be
encountered. If you install or perform service on equipment, it is your responsibility to read and obey these
warnings to guard against any bodily injury or property damage which may result to you or others.
PERSONAL INJURY OR DEATH HAZARDS
ELECTRICAL HAZARDS:
• Unplug and/or disconnect all electrical power to the unit before performing inspections,
maintenance, or service.
• Make sure to follow proper lockout/tag out procedures.
• Always work in the company of a qualified assistant if possible.
• Capacitors, even when disconnected from the electrical power source, retain an electrical charge
potential capable of causing electric shock or electrocution.
• Handle, discharge, and test capacitors according to safe, established, standards, and approved
procedures.
• Extreme care, proper judgment, and safety procedures must be exercised if it becomes necessary
to test or troubleshoot equipment with the power on to the unit.
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read
and obey all safety messages.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury,
and tell you what will happen if the instructions are not followed.
This is a safety Alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol with the word “WARNING”
or “CAUTION”. These words mean:
You can be killed or seriously injured if you do not follow instructions.
You can receive minor or moderate injury if you do not follow instructions.
A message to alert you of potential property damage will have the
word “NOTICE”. Potential property damage can occur if instructions
are not followed.
WARNING
CAUTION
NOTICE
2

• Do not spray or pour water on the return air grille, discharge air grille, evaporator coil, control panel,
and sleeve on the room side of the air conditioning unit while cleaning.
• Electrical component malfunction caused by water could result in electric shock or other electrically
unsafe conditions when the power is restored and the unit is turned on, even after the exterior is dry.
• Never operate the A/C unit with wet hands.
• Use air conditioner on a single dedicated circuit within the specified amperage rating.
• Use on a properly grounded circuit only.
• Do not use extension cords with the unit.
• Follow all safety precautions and use proper and adequate protective safety aids such as: gloves,
goggles, clothing, adequately insulated tools, and testing equipment etc.
• Failure to follow proper safety procedures and/or these warnings can result in serious injury or death.
REFRIGERATION SYSTEM HAZARDS:
• Use approved standard refrigerant recovering procedures and equipment to relieve pressure before
opening system for repair.
• Do not allow liquid refrigerant to contact skin. Direct contact with liquid refrigerant can result in minor
to moderate injury.
• Be extremely careful when using an oxy-acetylene torch. Direct contact with the torch’s flame or hot
surfaces can cause serious burns.
• Make sure to protect personal and surrounding property with fire proof materials.
• Have a fire extinguisher at hand while using a torch.
• Provide adequate ventilation to vent off toxic fumes, and work with a qualified assistant whenever
possible.
• Always use a pressure regulator when using dry nitrogen to test the sealed refrigeration system for
leaks, flushing etc.
• Make sure to follow all safety precautions and to use proper protective safety aids such as: gloves,
safety glasses, clothing etc.
• Failure to follow proper safety procedures and/or these warnings can result in serious injury or death.
MECHANICAL HAZARDS:
• Extreme care, proper judgment and all safety procedures must be followed when testing,
troubleshooting, handling, or working around unit with moving and/or rotating parts.
• Be careful when, handling and working around exposed edges and corners of sleeve, chassis, and
other unit components especially the sharp fins of the indoor and outdoor coils.
• Use proper and adequate protective aids such as: gloves, clothing, safety glasses etc.
• Failure to follow proper safety procedures and/or these warnings can result in serious injury or death.
3

PROPERTY DAMAGE HAZARDS
FIRE DAMAGE HAZARDS:
• Read the Installation/Operation Manual for this air conditioning unit prior to operating.
• Use air conditioner on a single dedicated circuit within the specified amperage rating.
• Connect to a properly grounded circuit only.
• Do not use extension cords with the unit.
• Failure to follow these instructions can result in fire and minor to serious property damage.
WATER DAMAGE HAZARDS:
• Improper installation maintenance, or servicing of the air conditioner unit, or not following the above
Safety Warnings can result in water damage to personal items or property.
• Insure that the unit has a sufficient pitch to the outside to allow water to drain from the unit.
• Do not drill holes in the bottom of the drain pan or the underside of the unit.
• Failure to follow these instructions can result in result in damage to the unit and/or minor to serious
property damage.
4
INTRODUCTION
This service manual is designed to be used in conjunction with the operation and installation manual provided
with each unit.
This service manual was written to assist the professional HVAC service technician to quickly and accurately
diagnose and repair any malfunctions of this product.
This manual, therefore, will deal with all subjects in a general nature. (i.e. All text will pertain to all models).
IMPORTANT:It will be necessary for you to accurately identify the unit you are servicing, so
you can be certain of a proper diagnosis and repair. (See Unit Identification.)
Condenser
Air Discharge
Compressor
Fan Blade
Capillary Tubes
Bypass Valve
Electrical
Compartment
On/Off Switch
Thermostat
Air Intake
Air Discharge
Front Cover
Air Discharge
Vents
Sleeve
Indoor Blower
Wheel
Air Intake
Fan/Blower
Motor
Condenser
Condenser
Shroud Brace
Condenser Coil
Condenser/Fan Blade
Shroud

Serial Number
Decade Manufactured
L=0 C=3 F=6 J=9
A=1 D=4 G=7
B=2 E=5 H=8
A A A R 00001
Production Run Number
Year Manufactured
A=1 D=4 G=7 K=0
B=2 E=5 H=8
C=3 F=6 J=9
Product Line
R = RAC
Month Manufactured
A=Jan D=Apr G=Jul K=Oct
B=Feb E=May H=Aug L=Nov
C=Mar F=Jun J=Sept M=Dec
1st Digit – Function
S = Straight Cool, Value Series
H = HazardGard
3rd and 4th Digit - Approximate
BTU/HR (Cooling)
Heating BTU/Hr capacity listed in the
Specifi cation/Performance Data Section
7th Digit – Options
0 = Straight Cool &
6th Digit – Voltage
3 = 230-208 Volts
Model Number Code
S H 15 M 3 0 A - A
RAC Serial Number Identification Guide
UNIT IDENTIFICATION
5
5th Digit - Model Series/Year Introduced
M=2010
8th Digit – Marketing Suffix
Indicates Modification
(Subject to change)
9th Digit – Engineering Suffix
Indicates Modification
(Subject to change)

UL Listed for use in Class I, Division 2, Groups A, B, C
and D hazardous locations.
Hazardgard is specically designed to cool living quarters, storage areas
and other enclosures situated in hazardous locations, where specic volatile
ammable liquids or gases are handled or used within enclosed containers
or systems.
For more than 30 years, the Friedrich Hazardgard has endured some of the
toughest and most unforgiving operating conditions imaginable. Time-tested
in the eld where it counts, Hazardgard is trusted by professionals who have
to get the job done. Robust engineering with design details like 33% thicker
ns extend the life of the coil. Diamonblue
Technology, our anti-corrosive treatment,
provides added endurance and protection
in coastal or corrosive environments.
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Oshore oil rigs, on-shore oil company
ofces and reneries
Petrochemical sites and propane ll-up
stations
Paint and varnish storage or processing
plants
Grain alcohol processors or storage sites
Plant areas using strong solvents or
chemicals
Munitions plants or armories
PVC or plastics plants and processing
points
Recycling plants
Furniture renishing/stripping
workshops
Fertilizer plants
Ofce complexes where methane is a
by-product
Hazardous materials storage
Ideal applications
|HAZARDOUS DUTY |
6
HAZARDGARD APPLICATION

SPECIFICATIONS AND PERFORMANCE DATA
7
Due to continuing engineering research and technology, specL¿cations are subject to change without notice. Manufactured under U.S. Design Patent
DES 368, 306 decorative front; Utility Patent 5, 622, 058. MAXIMUM outdoor ambient operating temperature is 130°F. MAXIMUM TEMPERATURE
RATING FOR CLASS I, DIVISION 2, GROUPS A,B,C,D.
OPERATING TEMPERATURE CODE T3B
Specications
Installation Information
Model
Cooling Capacity Electrical Characteristics (60 Hertz)
Energy
Efficiency
Ratio AHAM
Moisture
Removal
Air Direction
Controls
Room Side Air
Circulation
(BTU/Hr.- AHAM) Volts Rated Amps AHAM Watts EER (Pints/ Hr.) CFM
SH15M30*14500/14000 230/208 6.9/7.4 1495/1443 9.7/9.7 6.0 8-way 375
SH20M30*19500/19000 230/208 9.1/10.0 2074/2021 9.4/9.4 4.0 8-way 375
Model
Dimensions
(Inches) Window Width
(Inches)
Thru-The-Wall
Finished Hole (Inches)
Circuit Rating
Breaker or
T - D Fuse
Weight
(Lbs.)
Height Width
Depth
Overall
Depth J Box
to Louvers
Minimum
Extension
Into Room
Minimum
Extension
Outside Min.Max .Height Width Max. Depth Volts - Amps Net Shipping
SH15M30*15 15/16 25 15/16 27 3/86 3 1/
16 16 15/16 27 7
/842 16 3/
16 26 3/
16 6 250V - 15A 156 168
SH20M30*17 15/16 25 15/16 27 3/86 3 1/
16 16 15/16 27 7
/842 18 3/
16 26 3/
16 6 250V - 15A 160 174
(A)
Front
SIDE VIEW
(A)
Junction
Box
Max.
Wall
Depth
S TANDARD ON ALL M ODE L S .
This advanced corrosion protection
treatment protects the outdoor coil
against deterioration and extends
the life of the unit especially in harsh
coastal environments.
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All models use
environmentally
friendly R-410A
refrigerant.
R-410A
7
Cooling Performance Data *
EVAPORATOR AIR
TEMP. DEG. F CONDENSER
TEMPERATURE
DEG. F
Discharge
Temp
Suction
Temp
Super
Heat
Sub-
Cooling
OPERATING
PRESSURES ELECTRICAL RATINGS R-410A REF.
Voltage
BREAKER
FUSE
Discharge
Air Temp. Drop F. Suction Discharge Amps Cool Amps Heat Locked Rotor Amps Charge in OZ. 60 Hertz Amps
SH15M30
*
54 26 127 186 67 18 35 137 480 6.9 - 43 50 208 / 230 15
SH15M30
*
54 26 185 124 68 15 38 137 485 9.1 - 43 42.7 208 / 230 15
* Due to continuing research in new energy-saving technology, performance data and 8th and 9th character are subject to change without notice.

ELECTRICAL DATA
ELECTRICAL REQUIREMENTS
ELECTRIC SHOCK HAZARD
WARNING
Turn off electric power before service or
installation.
All electrical connections and wiring MUST be
installed by a qualified electrician and conform to
the National Electrical Code and all local codes
which have jurisdiction.
Failure to do so can result in personal injury or
death.
Not following the above WARNING could result in fire or
electrically unsafe conditions which could cause moderate
or serious property damage.
Read, understand and follow the above warning.
NOTICE
FIRE HAZARD
ALL FIELD WIRING MUST MEET THE REQUIREMENTS OF THE NATIONAL ELECTRICAL CODE (ANSI/NFPA 70)
ARTICLE 501.
THE FIELD-PROVIDED CIRCUIT PROTECTION DEVICE (HACR CIRCUIT BREAKER OR TIME DELAY FUSE)
MUST NOT EXCEED THE AMPACITY INDICATED ON THE PRODUCT NAMEPLATE.
IMPORTANT: Before you begin the actual installation of your air conditioner, check local electrical codes and the
information below.
Your air conditioner must be connected to a power supply with the same A.C. voltage and frequency (hertz) as marked
on the data plate located on the chassis. Only alternating current (A.C.), no direct current (D.C.), can be used.
An overloaded circuit will invariably cause malfunction or failure of the air conditioner therefore, it is extremely important
that the electrical power is adequate. Consult your power company if in doubt.
Model Number Connection Type Circuit Rating
Time Delay Fuse
SH15 Junction Box 250V-15 Amp
SH20 Junction Box 250V-15 Amp
8

Permanent Split-Capacitor, totally enclosed fan motor
to assure efficient operation even under adverse
electrical conditions. Motor has a special stainless
steel shaft to resist corrosion and a hermetically sealed
overload for arc-free operation.
High capacity compressor with internal hermetically
sealed overload.
Solid-state relay contains transient voltage suppressor
to protect controls against transient voltage spikes.
Provides solid state switches for arc-free operation.
Hot gas bypass low ambient control to permit operation
without freezing at outdoor ambient temperatures as
low as 45°F (7°C).
Environmentally sealed on-off switch and gold plated
contacts in thermostat for corrosion resistance.
Electrodeposited epoxy primer and alkyd enamel, both
oven-baked for an attractive, long-lasting finish.
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
Copper tubing/aluminum fin coils.
Galvanized steel cabinet and base pan, all bonderized.
Slide-out chassis for easy installation in window or
through–the–wall.
Extra insulation inside, including completely insulated
plenum chamber for quieter, more efficient cooling.
Entire unit test run in environmental chamber before
crating.
Eight–way air flow control for uniform air circulation.
Condensate drain with exclusive mosquito trap.
15 amp circuit with time-delay fuse required.
Accommodates direct wiring.
Long lasting 3/8” (10mm) thick air filter, germicidally
treated, easily removed for cleaning.
Friedrich Air Conditioning quality has been proven by more than 25 years of successful experience from the Gulf
of Mexico to the searing sands of the Arabian desert.
Function Control (Power)
This switch is a double pole, single throw toggle switch.
ON - Turns everything on.
(Fan motor runs continuously)
OFF - Turns everything off.
Temperature Control
The knob at the bottom is the thermostat which is a cross
ambient type used to maintain the desired comfort level.
The thermostat reacts only to a change in temperature at
the bulb location - turn the knob clockwise to set cooler,
counterclockwise for warmer.
Friedrich leads with the first UL Listed Room Air
Conditioners designed to cool living quarters and other
enclosures situated in hazardous locations where specific
volatile flammable liquids or gases are handled or used with
enclosed containers or systems. Friedrich Hazardgard
room air conditioners are designed to meet the National
Electrical Code, Article 500 requirements for Class
I, Division 2, Groups A, B, C, D Hazardous locations,
and are the only air conditioners UL Listed for this
application. THIS UNIT IS LISTED BY UNDERWRITERS
LABORATORIES FOR USE IN CLASS I, DIVISION
2,GROUPS A, B, C, D HAZARDOUS LOCATIONS.
Operating Temperature Code: T3B.
HAZARDGARD SPECIAL FEATURES
Control Panel
Exclusive
9

COMPONENT DEFINITIONS
A. Mechanical components
B. Electrical components
C. Hermetic components
Plenum assembly
Diffuser with directional louvers used to direct the conditioned airflow.
Blower wheel
Attaches to the indoor side of the fan motor shaft and is used for distributing unconditioned, room side air through
the heat exchanger and delivering conditioned air into the room.
Slinger fan blade
Attaches to the outdoor side of the fan motor shaft and is used to move outside air through the condenser coil, while
slinging condensate water out of the base pan and onto the condenser coil, thus lowering the temperature and
pressures within the coil.
Thermostat Control
Used to maintain the specified room side comfort level.
System Switch
Used to regulate the operation of the fan motor and the compressor or to turn the unit off. For troubleshooting, refer
to the wiring diagrams and schematics in the back of this service manual.
Solid State Relay
Used to energize the compressor and fan motor. Each unit has 2, 50 amp, 208/230 volt relays.
Capacitor
Reduces line current and steadies the voltage supply, while greatly improving the torque characteristics of the fan
motor and compressor motor.
Fan Motor
Dual shafted fan motor operates the indoor blower wheel and the condenser fan blade simultaneously. (When unit
is turned on, the fan motor runs continuously).
Compressor
Motorized device used to compress refrigerant through the sealed system.
Low ambient bypass (hot gas bypass) valve
Used for low ambient cooling operation, the valve is connected between the discharge line at the compressor and
the suction process tube. It responds to suction pressure, whcih when reduced in the system, causes the valve to
open and bypass hot gas from the high pressure side to the low pressure side of the system. The valve is preset
to open when the suction pressure reaches 88 psig.
Capillary tube
A cylindrical metering device used to evenly distribute the flow of refrigerant to the heat exchanger (evaporator
coils).
10

FAN MOTOR
SWITCH, ON-OFF
Line side
SOLID STATE
RELAY
Load
side
LED indicates
contacts closed
when lit
FAN MOTOR
A 230 volt single phase permanent split capacitor motor
is used to drive the evaporator blower and condenser
fan. A running capacitor is wired across the start and run
terminals of the motor.
The motor is totally enclosed and is protected with a
line voltage overload located internally of the motor. The
motor shaft is stainless steel to resist corrosion. When
the unit is turned on, the motor runs continuously.
FAN MOTOR – TEST
1. Determine that the capacitor is good.
2. Perform continuity test on windings to determine if
open, shorted or okay.
SOLID STATE RELAY
Two 50 amp rated 208/230 volt solid state relays are used
to energize the compressor and fan motor. Terminals 3
and 4 are the 208/230 volt line side. Terminals 1 and 2
are load side contacts.
SYSTEM CONTROL SWITCH
This switch is double pole, single throw. Check for
continuity between terminals 2 and 3, and 5 and 6.
COMPONENT TESTING
CAPACITORS
Many motor capacitors are internally fused. Shorting the
terminals will blow the fuse, ruining the capacitor. A 20,000
ohm 2 watt resistor can be used to discharge capacitors
safely. Remove wires from capacitor and place resistor
across terminals. When checking a dual capacitor with
a capacitor analyzer or ohmmeter, both sides must be
tested.
Capacitor Check with Capacitor
Analyzer
The capacitor analyzer will show whether the capacitor
is “open” or “shorted.” It will tell whether the capacitor
is within its micro farads rating and it will show whether
the capacitor is operating at the proper power-factor
percentage. The instrument will automatically discharge
the capacitor when the test switch is released.
Capacitor Connections
The starting winding of a motor can be damaged by a
shorted and grounded running capacitor. This damage
usually can be avoided by proper connection of the
running capacitor terminals.
From the supply line on a typical 230 volt circuit, a 115 volt
potential exists from the “R” terminal to ground through a
possible short in the capacitor. However, from the “S” or
start terminal, a much higher potential, possibly as high as
400 volts, exists because of the counter EMF generated
in the start winding. Therefore, the possibility of capacitor
failure is much greater when the identified terminal is
connected to the “S” or start terminal. The identified
terminal should always be connected to the supply line, or
“R” terminal, never to the “S” terminal.
When connected properly, a shorted or grounded running
capacitor will result in a direct short to ground from the “R”
terminal and will blow the line fuse. The motor protector will
protect the main winding from excessive temperature.
ELECTRIC SHOCK HAZARD
WARNING
Turn off electric power before servicing.
Discharge capacitor with a 20,000 Ohm 2 Watt
resistor before handling.
Failure to do so may result in personal injury,
or death.
ELECTRIC SHOCK HAZARD
WARNING
Disconnect power to the unit before
servicing. Failure to follow this warning
could result in serious injury or death.
11

RANGE: Thermostat
(Part No. 618-225-02)
60°F ( ± 2°) to 90°F( ± 4°)
SENSING
BULB LOCATION
THERMOSTAT
A cross ambient thermostat is used to maintain the
desired comfort level. The thermostat reacts only to a
change in temperature at the bulb location. Important to
the successful operation of the unit is the position of the
sensing bulb in relation to the evaporator.
TESTING THE THERMOSTAT
Remove the wires from the 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 the
thermostat contacts open.
Note: The temperature must be within the range listed to
check the thermostat. Refer to the troubleshooting section
in this manual for additional information on thermostat
testing.
The Hazardgard unit is designed to operate at low outside
ambient temperatures. This is accomplished by the use
of a bypass valve installed in the refrigeration circuit.
The valve is connected between the discharge line at
the compressor and the suction process tube. The valve
responds to suction pressure which, when reduced in the
system, causes the valve to open and bypass hot gas
from the high pressure side to the low pressure side of
the system. The hot gas entering the compressor mixes
with the cool gas returned through the suction line, thus
increasing the suction pressure. The valve is preset to
open when the suction pressure reaches 88 psig. This
pressure setting cannot be altered. The system can be
operated at outdoor temperatures as low as 45°F before
the evaporator coil will begin to accumulate frost.
To determine if the valve operates, block the return air to
the evaporator coil. Turn on the unit and touch the tube
at the bypass valve outlet which connects to the suction
process tube. When the low side pressure reaches
approximately 88 psig, the valve will begin to open and
the tube will get hot. This method will determine if the
valve is responding to the suction pressure change.
LOW AMBIENT BYPASS VALVE
ELECTRIC SHOCK HAZARD
WARNING
Disconnect power to the unit before
servicing. Failure to follow this warning
could result in serious injury or death.
Sealed Refrigeration System contains
refrigerant and oil under high pressure.
Proper safety procedures must be followed,
and proper protective clothing must be
worn when working with refrigerants.
Failure to follow these procedures could
result in serious injury or death.
WARNING
HIGH PRESSURE HAZARD
LOW AMBIENT
BYPASS VALVE
12

• R-410A pressure is approximately 60% higher than R-22 pressure.
• R-410A cylinders must not be allowed to exceed 125 F, they may leak or rupture.
• R-410A must never be pressurized with a mixture of air, it may become
flammable.
• Servicing equipment and components must be specifically designed for use with R-410A and
dedicated to prevent contamination.
• Manifold sets must be equipped with gauges capable of reading 750 psig (high side) and 200
psig (low side), with a 500-psig low-side retard.
• Gauge hoses must have a minimum 750-psig service pressure rating
• Recovery cylinders must have a minimum service pressure rating of 400 psig, (DOT 4BA400
and DOT BW400 approved cylinders).
• POE (Polyol-Ester) lubricants must be used with R-410A equipment.
• To prevent moisture absorption and lubricant contamination, do not leave the refrigeration
system open to the atmosphere longer than 1 hour.
• Weigh-in the refrigerant charge into the high side of the system.
• Introduce liquid refrigerant charge into the high side of the system.
• For low side pressure charging of R-410A, use a charging adaptor.
• Use Friedrich approved R-410A filter dryers only.
The following is a list of important considerations when working with R-410A equipment
R-410A SEALED SYSTEM REPAIR CONSIDERATIONS
Do not puncture, heat, expose to flame or incinerate.
Only certified refrigeration technicians should
service this equipment.
R410A systems operate at higher pressures than
R22 equipment. Appropriate safe service and
handling practicces must be used.
Only use gauge sets designed for use with R410A.
Do not use standard R22 gauge sets.
WARNING
Refrigeration system under high pressure
13

Proper refrigerant charge is essential to proper unit operation.
Operating a unit with an improper refrigerant charge will
result in reduced performance (capacity) and/or efficiency.
Accordingly, the use of proper charging methods during
servicing will insure that the unit is functioning as designed
and that its compressor will not be damaged.
Too much refrigerant (overcharge) in the system is just as bad
(if not worse) than not enough refrigerant (undercharge). They
both can be the source of certain compressor failures if they
remain uncorrected for any period of time. Quite often, other
problems (such as low air flow across evaporator, etc.) are
misdiagnosed as refrigerant charge problems. The refrigerant
circuit diagnosis chart will assist you in properly diagnosing
these systems.
An overcharged unit will at times return liquid refrigerant
(slugging) back to the suction side of the compressor eventually
causing a mechanical failure within the compressor. This
mechanical failure can manifest itself as valve failure, bearing
failure, and/or other mechanical failure. The specific type of
failure will be influenced by the amount of liquid being returned,
and the length of time the slugging continues.
Not enough refrigerant (undercharge) on the other hand, will
cause the temperature of the suction gas to increase to the point
where it does not provide sufficient cooling for the compressor
motor. When this occurs, the motor winding temperature will
increase causing the motor to overheat and possibly cycle open
the compressor overload protector. Continued overheating of
the motor windings and/or cycling of the overload will eventually
lead to compressor motor or overload failure.
Sealed Refrigeration System contains refrigerant
and oil under high pressure.
Proper safety procedures must be followed,
and proper protective clothing must be worn
when working with refrigerants.
Failure to follow these procedures could
result in serious injury or death.
WARNING
HIGH PRESSURE HAZARD
Unplug and/or disconnect all electrical power
to the unit before performing inspections,
maintenances or service.
Failure to do so could result in electric shock,
serious injury or death.
WARNING
RISK OF ELECTRIC SHOCK
R-410A SEALED REFRIGERATION SYSTEM REPAIRS
SEALED SYSTEM REPAIRS TO COOL-ONLY MODELS REQUIRE THE INSTALLATION OF A LIQUID LINE DRIER.
IMPORTANT
EQUIPMENT REQUIRED:
1. Voltmeter
2. Ammeter
3. Ohmmeter
4. E.P.A. Approved Refrigerant Recovery System
5. Vacuum Pump (capable of 200 microns or less
vacuum.)
6. Acetylene Welder
7. Electronic Halogen Leak Detector capable of
detecting HFC (Hydrofluorocarbon) refrigerants.
8. Accurate refrigerant charge measuring device such
as:
a. Balance Scales - 1/2 oz. accuracy
b. Charging Board - 1/2 oz. accuracy
9. High Pressure Gauge - (0 to 750 lbs.)
10. Low Pressure Gauge - (-30 to 200 lbs.)
11. Vacuum Gauge - (0 - 1000 microns)
12. Facilities for flowing nitrogen through refrigeration tubing
during all brazing processes.
EQUIPMENT MUST BE CAPABLE OF:
1. Recovering refrigerant to EPA required levels.
2. Evacuation from both the high side and low side of the
system simultaneously.
3. Introducing refrigerant charge into high side of the
system.
4. Accurately weighing the refrigerant charge introduced
into the system.
14
Refrigerant Charging
NOTE: Because the Hazardgard refrigeration system is
sealed, service process tubes will have to be installed. First
install a line tap and remove refrigerant from the system.
Make necessary sealed system repairs and vacuum system.
Crimp process tube line and solder end shut. Do not leave a
service valve in the sealed system.

3. Install a process tube to sealed system.
4. Make necessary repairs to system.
5. Evacuate system to 200 microns or less.
6. Weigh in refrigerant with the proper quantity of R-410A
refrigerant.
7. Start unit, and verify performance.
8. Crimp the process tube and solder the end shut.
Proper safety procedures must be followed,
and proper protective clothing must be worn
when working with a torch.
Failure to follow these procedures could
result in moderate or serious injury.
Proper safety procedures must be followed,
and proper protective clothing must be worn
when working with liquid refrigerant.
Failure to follow these procedures could
result in minor to moderate injury.
WARNING
CAUTION
BURN HAZARD
FREEZE HAZARD
Proper safety procedures must be followed,
and proper protective clothing must be worn
when working with a torch.
Failure to follow these procedures could
result in moderate or serious injury.
WARNING
BURN HAZARD
Method Of Charging / Repairs
The acceptable method for charging the Hazardgard system
is the Weighed in Charge Method. The weighed in charge
method is applicable to all units. It is the preferred method to
use, as it is the most accurate.
The weighed in method should always be used whenever
a charge is removed from a unit such as for a leak repair,
compressor replacement, or when there is no refrigerant
charge left in the unit. To charge by this method, requires the
following steps:
1. Install a piercing valve to remove refrigerant from the
sealedsystem. (Piercing valve must be removed from the
system before recharging.)
2. Recover Refrigerant in accordance with EPA regulations.
15

Undercharged Refrigerant Systems
An undercharged system will result in poor performance
(low pressures, etc.) in both the heating and cooling
cycle.
Whenever you service a unit with an undercharge of
refrigerant, always suspect a leak. The leak must be
repaired before charging the unit.
To check for an undercharged system, turn the unit on,
allow the compressor to run long enough to establish
working pressures in the system (15 to 20 minutes).
During the cooling cycle you can listen carefully at the exit
of the metering device into the evaporator; an intermittent
hissing and gurgling sound indicates a low refrigerant
charge. Intermittent frosting and thawing of the evaporator
is another indication of a low charge, however, frosting
and thawing can also be caused by insufficient air over
the evaporator.
Checks for an undercharged system can be made at
the compressor. If the compressor seems quieter than
normal, it is an indication of a low refrigerant charge.
Overcharged Refrigerant Systems
A check of the amperage drawn by the compressor
motor should show a lower reading. (Check the Unit
Specification.) After the unit has run 10 to 15 minutes,
check the gauge pressures. Gauges connected to system
with an undercharge will have low head pressures and
substantially low suction pressures.
of the evaporator will not be encountered because the
refrigerant will boil later if at all. Gauges connected to
system will usually have higher head pressure (depending
upon amount of over charge). Suction pressure should be
slightly higher.
Compressor amps will be near normal or higher.
Noncondensables can also cause these symptoms. To
confirm, remove some of the charge, if conditions improve,
system may be overcharged. If conditions don’t improve,
Noncondensables are indicated.
Whenever an overcharged system is indicated, always
make sure that the problem is not caused by air flow
problems. Improper air flow over the evaporator coil may
indicate some of the same symptoms as an over charged
system.
An overcharge can cause the compressor to fail, since it
would be “slugged” with liquid refrigerant.
The charge for any system is critical. When the compressor
is noisy, suspect an overcharge, when you are sure that
the air quantity over the evaporator coil is correct. Icing
ELECTRIC SHOCK HAZARD
WARNING
Turn off electric power before service or
installation.
Extreme care must be used, if it becomes
necessary to work on equipment with power
applied.
Failure to do so could result in serious injury or
death.
Sealed Refrigeration System contains refrigerant
and oil under high pressure.
Proper safety procedures must be followed,
and proper protective clothing must be worn
when working with refrigerants.
Failure to follow these procedures could
result in serious injury or death.
WARNING
HIGH PRESSURE HAZARD
16

Restricted Refrigerant System
Troubleshooting a restricted refrigerant system can be
difficult. The following procedures are the more common
problems and solutions to these problems. There are two
types of refrigerant restrictions: Partial restrictions and
complete restrictions.
A partial restriction allows some of the refrigerant to
circulate through the system.
With a complete restriction there is no circulation of
refrigerant in the system.
Restricted refrigerant systems display the same symptoms
as a “low-charge condition.”
When the unit is shut off, the gauges may equalize very
slowly.
Gauges connected to a completely restricted system will
run in a deep vacuum. When the unit is shut off, the gauges
will not equalize at all.
A quick check for either condition begins at the evaporator.
With a partial restriction, there may be gurgling sounds
at the metering device entrance to the evaporator. The
evaporator in a partial restriction could be partially frosted
or have an ice ball close to the entrance of the metering
device. Frost may continue on the suction line back to the
compressor.
Often a partial restriction of any type can be found by feel,
as there is a temperature difference from one side of the
restriction to the other.
With a complete restriction, there will be no sound at the
metering device entrance. An amperage check of the
compressor with a partial restriction may show normal
current when compared to the unit specification. With a
complete restriction the current drawn may be considerably
less than normal, as the compressor is running in a deep
vacuum (no load.) Much of the area of the condenser will
be relatively cool since most or all of the liquid refrigerant
will be stored there.
The following conditions are based primarily on a system
in the cooling mode.
17

Locked Rotor Voltage (L.R.V.) Test
Locked rotor voltage (L.R.V.) is the actual voltage available
at the compressor under a stalled condition.
Single Phase Connections
Disconnect power from unit. Using a voltmeter, attach one
lead of the meter to the run “R” terminal on the compressor
and the other lead to the common “C” terminal of the com-
pressor. Restore power to unit.
Determine L.R.V.
Start the compressor with the volt meter attached; then stop
the unit. Attempt to restart the compressor within a couple
of seconds and immediately read the voltage on the meter.
The compressor under these conditions will not start and will
usually kick out on overload within a few seconds since the
pressures in the system will not have had time to equalize.
Voltage should be at or above minimum voltage of 197 VAC,
as specified on the rating plate. If less than minimum, check
for cause of inadequate power supply; i.e., incorrect wire
size, loose electrical connections, etc.
ELECTRIC SHOCK HAZARD
WARNING
Turn off electric power before service or
installation. Extreme care must be used, if it
becomes necessary to work on equipment with
power applied.
Failure to do so could result in serious injury or
death.
COMPRESSOR CHECKS
Amperage (L.R.A.) Test
The running amperage of the compressor is the most impor-
tant of these readings. A running amperage higher than that
indicated in the performance data indicates that a problem
exists mechanically or electrically.
Single Phase Running and L.R.A. Test
NOTE: Consult the specification and performance section
for running amperage. The L.R.A. can also be found on the
rating plate.
Select the proper amperage scale and clamp the meter
probe around the wire to the “C” terminal of the compressor.
Turn on the unit and read the running amperage on the me-
ter. If the compressor does not start, the reading will indicate
the locked rotor amperage (L.R.A.).
ELECTRIC SHOCK HAZARD
WARNING
Turn off electric power before service or
installation. Extreme care must be used, if it
becomes necessary to work on equipment with
power applied.
Failure to do so could result in serious injury or
death.
18
1. With no power to unit, remove the leads from the com-
pressor terminals.
2. Using an ohmmeter, test continuity between terminals
C-S and C-R. If no continuity, the compressor overload
is open and the compressor must be replaced.
CHECKING THE INTERNAL OVERLOAD
INTERNAL OVERLOAD
Should the internal temperature and/or current draw become
excessive, the contacts in the overload will open, turning off
the compressor. The overload will automatically reset, but
may require several hours before the heat is dissipated.
Internal Overload
ELECTRIC SHOCK HAZARD
WARNING
Disconnect power to the unit before
servicing. Failure to follow this warning
could result in serious injury or death.
The compressors are equipped with an internal overload.
The overload is embedded in the motor windings to sense
the winding temperature and/or current draw. The overload
is connected in series with the common motor terminal

Many compressor failures are caused by the following
conditions:
1. Improper air flow over the evaporator.
2. Overcharged refrigerant system causing liquid to be
returned to the compressor.
3. Restricted refrigerant system.
4. Lack of lubrication.
5. Liquid refrigerant returning to compressor causing oil
to be washed out of bearings.
6. Noncondensables such as air and moisture in
the system. Moisture is extremely destructive to a
refrigerant system.
Single Phase Resistance Test
Remove the leads from the compressor terminals and set
the ohmmeter on the lowest scale (R x 1).
Touch the leads of the ohmmeter from terminals common
to start (“C” to “S”). Next, touch the leads of the ohmmeter
from terminals common to run (“C” to “R”).
Add values “C” to “S” and “C” to “R” together and
check resistance from start to run terminals (“S” to “R”).
Resistance “S” to “R” should equal the total of “C” to “S”
and “C” to “R.”
In a single phase PSC compressor motor, the highest
value will be from the start to the run connections (“S” to
“R”). The next highest resistance is from the start to the
common connections (“S” to “C”). The lowest resistance
is from the run to common. (“C” to “R”) Before replacing a
compressor, check to be sure it is defective.
Check the complete electrical system to the compressor
and compressor internal electrical system, check to be
certain that compressor is not out on internal overload.
Complete evaluation of the system must be made
when ever you suspect the compressor is defective.
If the compressor has been operating for sometime, a
careful examination must be made to determine why the
compressor failed.
19
Recommended procedure for compressor
replacement
1. Be certain to perform all necessary electrical and
refrigeration tests to be sure the compressor is
actually defective before replacing.
2. Recover all refrigerant from the system though
the process tubes. PROPER HANDLING OF
RECOVERED REFRIGERANT ACCORDING TO
EPA REGULATIONS IS REQUIRED. Do not use
gauge manifold for this purpose if there has been
a burnout. You will contaminate your manifold and
hoses. Use a Schrader valve adapter and copper
tubing for burnout failures.
Unplug and/or disconnect all electrical power
to the unit before performing inspections,
maintenances or service.
Failure to do so could result in electric shock,
serious injury or death.
WARNING
RISK OF ELECTRIC SHOCK
Sealed Refrigeration System contains refrigerant
and oil under high pressure.
Proper safety procedures must be followed,
and proper protective clothing must be worn
when working with refrigerants.
Failure to follow these procedures could
result in serious injury or death.
WARNING
HIGH PRESSURE HAZARD
Extreme care, proper judgment and all safety
procedures must be followed when testing,
troubleshooting, handling or working around
unit while in operation with high temperature
components. Wear protective safety aids
such as: gloves, clothing etc.
Failure to do so could result in serious burn
injury.
WARNING
HIGH TEMPERATURES
The use of a torch requires extreme care and proper
judgment. Follow all safety recommended precautions
and protect surrounding areas with fire proof materials.
Have a fire extinguisher readily available. Failure to follow
this notice could result in moderate to serious property
damage.
NOTICE
FIRE HAZARD
COMPRESSOR REPLACEMENT