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SNOWBIRD TECHNOLOGIES S18K-LW-1 Technical Manual

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SNOWBIRD TECHNOLOGIES
COMMERCIAL/TECHNICAL MANUAL
AIR CONDITIONER, HORIZONTAL COMPACT,
LIGHTWEIGHT 18,000 BTU/HR
208 VOLT, 3 PHASE, 50/60 HERTZ,
ENVIRONMENTAL SYSTEMS S18K-LW-1
i

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  • Page 1 SNOWBIRD TECHNOLOGIES COMMERCIAL/TECHNICAL MANUAL AIR CONDITIONER, HORIZONTAL COMPACT, LIGHTWEIGHT 18,000 BTU/HR 208 VOLT, 3 PHASE, 50/60 HERTZ, ENVIRONMENTAL SYSTEMS S18K-LW-1...
  • Page 2 WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual.
  • Page 3 WARNING DEATH ON CONTACT or severe injury may result if personnel fail to observe safety precautions. Always disconnect the air conditioner from power source before performing maintenance on this equipment. Make sure equipment is grounded at all times. If power must remain on for troubleshooting, exercise extreme care to avoid contact with any electrical component, fan, fan motor, etc.
  • Page 4 HAZARDOUS MATERIALS DESCRIPTION WARNING WARNING OIL AND REFRIGERANT Avoid inhaling fumes from acid formed by burn out of oil and refrigerant. Wear an air filtering mask if area is not thoroughly ventilated. Wear protective goggles or glasses to protect eyes. Wear rubber gloves to protect hands.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS WARNING SUMMARY HOW TO USE THIS MANUAL SECTION CHAPTER 1 – GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION General Information........................0001 00 Equipment Description and Data ....................0002 00 Theory of Operation ........................0003 00 CHAPTER 2 – OPERATOR INSTRUCTIONS Description and Use of Operator Controls and Indicators ..............
  • Page 6 Wire L ists and Schematic Diagrams....................0040 00 Installation Hardware Maintenance ....................0041 00 CHAPTER 7 – D IRECT SUPPORT TROUBLESHOOTING PROCEDURES Direct Support Troubleshooting Introduction................. 0042 00 Direct Support Malfunction/System Index ..................0043 00 Direct Support Troubleshooting Procedures................... 0044 00 CHAPTER 8 –...
  • Page 7 You must familiarize yourself with the entire maintenance procure before beginning any maintenance task. When first receiving this instrument, start at the front of the manual and go all the way through to the back. Become familiar with every part of this manual and the air conditioners S18K-LW-1.

  • Page 8: Theory Of Operation

    CHAPTER 1 INTRODUCTION INFORMATION WITH THEORY OF OPERATION...
  • Page 10 Type of Manual: Operator’ s , Unit, Direct Support, and G eneral Support Maintenance Manual. Model Number and Equipment Names: S18K-LW-1 Air Conditioner, Compact, Horizontal, 18,000 BTU/Hr, 208 Volt, 3 Phase 50/60 Hz. OZONE DEPLETING SUBSTANCES (ODS) The 18K air conditioner utilizes R-410A as the refrigerant.
  • Page 11 0001 00 PREPARATION FOR STORAGE OR SHIPMENT Short Term Storage 1. Disconnect power supply and remove from shelter. 2. Make sure unit is clean and dry. 3. Close all louvers and grilles. 4. Unroll canvas cover and snap into place. 5.
  • Page 12 0001 00 0001 00-3...
  • Page 13 0001 00 WARRANTY INFORMATION The 18K BTU air conditioner is warrantied for 12 months from purchase date as etched on the serial tag. ABBREVIATIONS/ACRONYMS Abbreviation/Acronym Alternating Current Basic Issue Item Built-In Test British Thermal Unit Chemical, Biological, Radiological Change COEI Component of End Item Corrosion Prevention and Control Direct Current...
  • Page 14 0001 00 END OF SECTION 0001 00-5/6 blank...
  • Page 16 AIR CONDITIONER, COMPACT, HORIZONTAL DESCRIPTION AND DATA EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES The air conditioner is a horizontal compact air conditioner with a nominal cooling capacity of 18,000 British Thermal Units per hour (BTU/hr) and a nominal heating capacity of 13,400 BTU/hr. The air conditioner is intended primarily for use in mobile technical electronics shelters.
  • Page 17 0002 REAR VIEW FRONT VIEW Figure 1. Location of Major Components 0002 00-2...
  • Page 18 0002 LOCATION AND CONTENTS OF IDENTIFICATION PLATES Refer to Table 2-1 for the listing of figure reference and description for each identification plate location. Table 2-1. Identification Plates Figure Description Nomenclature Indication Caution Decal Unit Weight 175# Two Man Lift is Required Use Mechanical Lift if Available.
  • Page 19 0002 00 Figure 1. Location of Data Plates Figure 2. Equipment Data Plate (S18K-LW-1 Unit) 0002 00-4...
  • Page 20 0002 00 Figure 3. High Pressure Charging Valve Decal Figure 4. Access Cover Marking Figure 5. Low Pressure Charging Valve Decal 0002 00-5...
  • Page 21 0002-00 Figure 6 . Refrigeration Schematic Diagram Plate (S18K-LW-1 Unit)
  • Page 22 0002 00 Figure 7. Refrigeration Schematic Diagram Plate (S18K-LW-1 Unit) 0002 00-7...
  • Page 23 0002 00 Figure 8. Grounding Lug Decal Figure 9. Caution Grounding Decal 0002 00-8...
  • Page 24 0002 00 Figure 10. Danger Decal CAUTION UNIT WEIGHS 175 POUNDS LIFTING REQUIRES 2 MEN Figure 11. Lift Caution Decal THIS UNIT CONTIANS R-410A REFRIGERANT Figure 12. R-410A Warning 0002 00-9...
  • Page 25 0002 00 Figure 13. Caution Decal S18K-LW-1 Unit Figure 20. Caution Decal 0002 00-10...
  • Page 26 0002 00 EQUIPMENT DATA Air Conditioners Part No. S18K-LW-1 Nomenclature S18K-LW-1 Air Conditioner, Horizontal, Compact, 18,000 BTU/HR, 208 Volt, Three-Phase, 50/60 Hertz Manufactured by Snowbird Environmental Systems Capacity: Cooling 18,000 BTU/HR (Nominal) Heating 13,400 BTU/HR (Nominal) Phase Three-Phase, S18K-LW-1 Hertz...
  • Page 27 0002 00 Dimensions and Weight Depth 27.94 inches (70.970 cm) Nominal Height 20 inches (50.8 cm) Nominal Width 30 inches (76.2 cm) Nominal Evaporator Air Discharge Grill 20.12 inches x 8.76 inches (51.10 x 22.25 cm) Nominal Evaporator Air Intake Grill 22.52 inches x 9.96 inches (57.20 x 25.30 cm) Nominal Weight 175 pounds (maximum)
  • Page 28 0003 00 AIR CONDITIONER, COMPACT, HORIZONTAL THEORY OF OPERATION TECHNICAL PRINCIPALS OF OPERATION Refrigeration Cycle – Cooling (Refer to Schematic) The refrigeration system removes heat from a given area. The refrigeration cycle (see Figure 1) is as follows: 1. The compressor (1) takes cold, low pressure refrigerant gas and compresses it to a high temperature, high pressure gas.
  • Page 29 0003 00 FIGURE 1.REFRIGERANT SCHAMATIC 0003 00-2...

  • Page 30: Chapter 2 - Operator Instructions

    CHAPTER 2 OPERATOR INSTRUCTIONS...
  • Page 31 0004 00 AIR CONDITIONER, COMPACT, HORIZONTAL DESCRIPTION AND U SE OF CONTROLS AND INDICATORS GENERAL The air conditioner is a self-contained and electric powered unit that provides 18,000 BTU/HR for cooling or 13,400 BTU/HR for heating. Once started, it operates automatically due to the relationship of the components, controls and instruments.
  • Page 32 0004 00 Alternate Input Power Operation The air conditioner is shipped from the manufacturer wired for operation to use the main input power connector (J1) located in the front of the unit next to the control module. END OF SECTION 0004 00-2...
  • Page 33 INITIAL SETUP Equipment Condition Mode selector switch in OFF position Correct voltage and phase power source (208 volts, three phase, 50/60 Hz for S18K-LW-1 unit) Perform operator PMCS (SEC 0010 00) as necessary General Installation Site Requirements A relatively level surface.
  • Page 34 0005 00 3. Roll up and tie the canvas cover. See Figure 1. CANVAS COVER (ROLLED UP) CANVAS COVER TIES TIES Figure 1. Canvas Cover 4. Ground the unit. 5. Connect the main power to the unit. 6. Open the evaporator intake louvers (see Figure 2) by moving the tabs up or down as required. Ensure evaporator discharge louvers are open by adjusting each louver individually.
  • Page 35 0005 00 ITEM # DESCRIPTION EVAP. RETURN & FILTER FRESH AIR VENT CONTROL (PULL CHAIN) JI POWER CONNECTOR RCM -TEMP/MODE SELECTOR SWITCHES CIRCUIT BREAKER GROUND LUG SCREW EVAP SUPPLY AIR & MIST ELIMINATOR HIGH PRESSURE CUT-OUT RESET BUTTON Figure 2. Air Conditioner Front View 7.
  • Page 36 0005 00 8. Turn the temperature selector switch to WARMER. See Figure 3. 9. Position circuit breaker to “ON”. 10. Position the mode selector switch to VENT, then position the mode selector switch to COOL. Cooling Operation CAUTION Do not operate the air conditioner in cool mode if the refrigerant is at a low level or if bubbles appear in sight glass.
  • Page 37 For safe operation, the air conditioner must be grounded prior to use. 1. Perform the preventive maintenance checks and services. 2. Check for the correct voltage and phase (208 volts, three-phase, 50/60 Hz for S18K-LW-1. 3. Roll up and tie canvas cover.
  • Page 38 0005 00 1. Position the mode selector switch to OFF. 2. Adjust the ventilation damper control to close the damper door. 3. If a shutdown is to be for an extended period, cover condenser side of unit with canvas cover and disconnect the power cable.
  • Page 39 0005 00 OPERATOR CONTROL SETTINGS Table 1 lists all operator control settings used during unit operation. Table 1. Operator Control Settings Mode Temperature Evaporator Fresh Air Evaporator Mode Selector Control Outlet Fabric Cover Damper Inlet Louver Switch Thermostat Louver Ventilate with VENT Does not Closed...
  • Page 41 INITIAL SETUP Equipment Condition Mode selector switch in OFF position Correct voltage and phase power source (208 volts, three phase, 50/60 Hz, S18K-LW-1.) General Installation Site Requirements A relatively level surface. An unobstructed flow of air from outside the area.
  • Page 42 0006 00 OPERATION IN EX TREME HEAT General The air conditioner is designed to operate satisfactorily at temperatures up to 120° F (49°C). If unit is operated at condenser inlet temperatures higher than 120°F (49°C), the cooling capacity will be lowered and long periods of operation at extended temperatures may cause compressor and condenser fan motor to overheat and trip their internal overload switches or the high pressure cutout switch to shut the unit off.
  • Page 43 0006 00 OPERATION IN SALT WATER AREAS WARNING Ensure power source is disconnected prior to washing the air conditioner. 1. General. Wash the exterior and the condenser section of the unit with clean fresh water at frequent intervals. Be careful not to damage electrical system with water. Special attention must be given to prevent rust and corrosion. 2.

  • Page 45: Operator Troubleshooting Introduction

    CHAPTER 3 OPERATOR TROUBLESHOOTING PROCEDURES...
  • Page 46 0007 OPERATOR TROUBLESHOOTING INTRODUCTION AIR CONDITIONER, COMPACT, HORIZONTAL MALFUNCTION/SYMPTOM INDEX The malfunction/symptom index (SEE SECTION 008) is a quick reference index for finding troubleshooting procedures. Associated with each symptom name is a section sequence number representing the starting point in a troubleshooting sequence.
  • Page 47 0007 00 CUIRCUIT BREAKER Figure 1. Air Conditioner Front View END OF SECTION 0007 00-2...
  • Page 48 0008 00 OPERATOR MALFUNCTIONS/SYMPTOM INDEX AIR CONDITIONER, COMPACT, HORIZONTAL TROUBLESHOOTING MALFUNCTION/SYMPTOM PROCEDURE Air Conditioner Fails to Operate Power cable not connected to proper voltage and phase or proper connector SEC 0009 00 J 1. Circuit breaker is OFF SEC 0009 00 Mode selector switch is in OFF position.
  • Page 49 0008 00 TROUBLESHOOTING MALFUNCTION/SYMPTOM PROCEDURE Faulty compressor contactor contacts. SEC 0013 00 Damage of mode selector switch. SEC 0013 00 Evaporator/Condenser Fan Motor Fails to Operate Faulty fan motor. SEC 0013 00 Evaporator/condenser fan or motor binding. SEC 0013 00 Poor continuity of wiring or terminals.
  • Page 50 0009 00 OPERATOR TROUBLESHOOTING PROCEDURES AIR CONDITIONER, COMPACT, HORIZONTAL THIS SECTION COVERS Air Conditioner Fails to Operate, Insufficient Cooling, No Heat or Low Heat INITIAL SETUP: Operator FAULT PROCEDURE 1. AIR CONDITIONER FAILS TO OPERATE. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION AIR CONDITIONER FAILS TO OPERATE.
  • Page 51 0009 00 FAULT PROCEDURE 2. INSUFFICIENT COOLING – Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 3. Determine that sufficient air is passing across evaporator coil by placing a piece of paper in front of the evaporator air intake louver. The paper should be held against the louver blades by the air. Open evaporator air intake louver blades.

  • Page 52: Chapter 4 - Operator Maintenance Instructions

    CHAPTER 4 OPERATOR MAINTENANCE INSTRUCTIONS...
  • Page 53 0010 00 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES AIR CONDITIONER, COMPACT, HORIZONTAL INITIAL SETUP: Operator INTRODUCTION General Preventive Maintenance Checks and Services (PMCS) (refer to Table 1) are performed to keep the air conditioner in operating condition. The checks are used to find, correct, or report problems. Operator is to do the PMCS jobs as shown in the PMCS table.
  • Page 54 0010 00 Table 1. Operator Preventive Maintenance Checks and Services (PMCS) NOTE Within designated intervals , these checks are to be performed in the order listed. Refer to Figure 1. ITE M ITEM TO BE EQUIPMENT NOT INTERVAL PROCEDURE CHECKED OR READY/AVAILABLE SERVICED Before...
  • Page 55 0010 00 Table 1. O p e rator Pre ventive Maintenance Checks and Services (PMCS) Continued ITEM TO BE EQUIPMENT NOT ITEM INTERVAL CHECKED OR PROCEDURE READY/AVAILABLE SERVICED During Liquid Sight After approximately 5 minutes in COOL Moisture or low charge Indicator mode operation, check for moisture and is indicated.

  • Page 56: Operator Preventive Maintenance Checks And Services (Pmcs)

    0010 00 Table 1. Operator Preventive Maintenance Checks and Services (PMCS) Continued ITEM TO BE EQUIPMENT NOT ITEM CHECKED OR PROCEDURE READY/AVAILABLE INTERVAL SERVICED After Panels and Covers Inspect for security of attachment and Panels and covers cleanliness. Report damaged condition to missing or severely Unit Maintenance personnel.
  • Page 57 0011 00 OPERATOR MAINTENANCE INSTRUCTIONS AIR CONDITIONER, COMPACT, HORIZONTAL SERVICE, CLEANING, ADJUST INITIAL SETUP: Personnel Required WARNING Ensure power source is disconnected before performing any maintenance function. WARNING Do not use compressed air for cleaning purposes except where reduced to less than 30 psi (2.1 kg/cm ) and then only with effective chip guarding and personnel protective equipment.
  • Page 58 0011 00 CANVAS COVER (TIED) FRESH AIR SCREEN CONDENSER GUARD Figure 1. Screens and Guards ADJUST Evaporator Louvers 1. Position the evaporator air intake louver (see Figure 2) so that the louvers are fully open when the ventilation damper door is in the closed position. Partially close the evaporator inlet louver when the ventilation damper door is in the open position.
  • Page 59 0011 00 Ventilation Damper Control 1. Check for binding; remove obstructions. 2. Brush off any loose dirt or foreign matter. 3. Inspect for security of attachment and damage. 4. Report damaged condition to unit maintenance personnel. 5. Adjust ventilation damper control to desired degree of fresh air. Remote Control Module Figure 3.

  • Page 60: Chapter 5 - Unit Troubleshooting

    CHAPTER 5 UNIT TROUBLESHOOTING...

  • Page 61: Unit Troubleshooting Introduction

    0012 00 UNIT TROUB LESHOOTING INTRODUCTION AIR CONDITIONER, COMPACT, HORIZONTAL MALFUNCTION/SYMPTOM INDEX The malfunction/symptom index (Section 0008 00) is a quick reference index for finding troubleshooting procedures. Associated with each symptom name is a section sequence number representing the starting point in a troubleshooting sequence.
  • Page 63 0013 00 UNIT TROUBLESHOOTING AIR CONDITIONER, COMPACT, HORIZONTAL THIS SECTION COVERS: Air Conditioner Fails to Operate, Insufficient Cooling, Fan Motor Fails to Operate, Compressor Will Not Start, Insufficient Heating INITIAL SETUP: Personnel Required Reference Section 0008 00, Malfunction/Symptom Index General This section provides information useful in diagnosing and correcting unsatisfactory operation or failure of the air conditioner.
  • Page 64 Connect power cable to receptacle. See SEC 0040 00 schematic diagram. Step 2. Make sure that you are using the correct voltage and phase. Check line voltage with multimeter for 208 VAC, three-phase, 50/60 Hz power (S18K-LW-1 unit). Step 3.
  • Page 65 0013 00 FAULT PROCEDURE 2. INSUFFICIENT COOLING - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION INSUFFICIENT COOLING Step 4. Inspect evaporator air intake filter for dirt. Clean filter. FAULT PROCEDURE 3. COMPRESSOR WILL NOT START. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION COMPRESSOR WILL NOT START WARNING Ensure the power source is disconnected.
  • Page 66 0013 00 FAULT PROCEDURE 4. INSUFFICIENT HEATING MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION INSUFFICIENT HEATING Step 1. Check that Mode Selector switch is in HEAT position. Switch to HEAT position. Replace bad Mode Selector switch. (Refer to SEC 0026 00). Step 2.

  • Page 67: Chapter 6 - Unit Maintenance Instructions

    CHAPTER 6 UNIT MAINTENANCE INSTRUCTIONS...
  • Page 68 0014 00 SERVICE UPON RECEIPT AIR CONDITIONER, COMPACT, HORIZONTAL THIS SECTION COVERS: Unloading, Unpacking, Checking Unpacked Equipment, Installation, Connect to Power Source, Operation, Check and Adjustment INITIAL SETUP: References Section 0002 00 (Location of Main Components) Section 0010 00 (Unit PMCS) Section 0026 00 (Main Power Input Connector) Section 0040 00 (Electronic Schematics) Personnel Required...
  • Page 69 0014 00 1. Remove shipping container. 2. Cut the metal bands that hold the top of the container to the base. 3. Inspect unit for any damage. WARNING Do not allow the unit to swing while suspended from a lifting device. Failure to observe this warning may result in injury to personnel and damage to the equipment.
  • Page 70 0014 00 Table 1. Service Upon Receipt Checklist LOCATION ITEM ACTION REFERENCE 1. Exterior Louvers, Covers, Drains, Guards, Perform operator PMCS before you SEC 0010 00 Controls, Switches operate. 2. Front Main Power Connectors a. Inspect connectors for damage. SEC 0029 00 b.
  • Page 71 0014 00 Grounding 1. Clean front of ground connection to obtain a bright metal surface. 2. Remove insulation from ends of grounding wire (10 AWG) or use bare ends. Make loop at wire ends. 3. Using ¼-20 nut and washer, attach one end of wire to air conditioner front panel ground stud. 4.
  • Page 72 Make sure the mode selector switch and circuit breaker are in the OFF position. 1. Connect a compatible air conditioner power cable to a 208 VAC, 50/60 Hz, three phase power source (S18K-LW-1) OPERATION CHECK AND ADJUSTMENTS 1. Check operation of unit.
  • Page 73 0014 00 Figure 1. Installation Dimensions (Sheet 1 of 2) 0014 00-6...
  • Page 74 0014 00 0014 00 Figure 2. Installatioin Dimensions (Sheet 2) 0014 00-7/8 blank...

  • Page 76: Unit Preventive Maintenance Checks And Services (Pmcs)

    0015 00 UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES AIR CONDITIONER, COMPACT, HORIZONTAL INITIAL SETUP: Personnel Required References SEC 0018 00 (Top cover) SEC 0020 00 (Louvers) SEC 0024 00 (Condensate drains) SEC 0028 00 (Electrical components) Wire List and Schematic Diagram (SEC 0040 00) Equipment Condition Main power source is disconnected.
  • Page 77 TM 9-4120-430-14 0015 00 WARNING Do not use compressed air for cleaning purposes, except when reduced to less than 30 psi (2.1 kg/cm ) and then only with effective chip guarding and personal protective equipment. “Interval” Column. Weekly and quarterly intervals are shown opposite the appropriate check. A weekly check is performed weekly.
  • Page 78 0015 00 Table 1. Unit Preventive Maintenance Checks and Services (PMCS) - Continued ITEM TO BE EQUIPMENT NOT ITEM INTERVAL CHECKED OR PROCEDURE READY/AVAILABLE SERVICED 4. Inspect louver (3) for bent blades. Straighten or replace. 5. Lubricate air filter (5) with filter-kote (Item 17, SEC 0085 00).
  • Page 79 0015 00 Table 1. Unit Preventive Maintenance Checks and Services (PMCS) - Continued ITEM TO BE EQUIPMENT NOT ITEM INTERVAL CHECKED OR PROCEDURE READY/AVAILABLE SERVICED media (3) for damage. Replace if damaged. 4. Clean mist eliminator (2) and filter media (3). 5.
  • Page 80 0015 00 Table 1. Unit Preventive Maintenance Checks and Services (PMCS) - Continued ITEM TO BE EQUIPMENT NOT ITEM INTERVAL CHECKED OR PROCEDURE READY/AVAILABLE SERVICED 4. Replace damaged impellers (3) or (4) or motors (1 and 2) (SEC 0035 00 and SEC 0037 00).
  • Page 81 0015 00 Table 1. Unit Preventive Maintenance Checks and Services (PMCS) - Continued ITEM TO BE EQUIPMENT NOT ITEM INTERVAL CHECKED OR PROCEDURE READY/AVAILABLE SERVICED Figure 5. Electric Heater Assembly Quarterly Evaporator Coil and Item is dirty, damaged 1. Inspect coils for dirt or damage. Clean Condenser Coil or leaking refrigerant.
  • Page 82 0015 00 Table 1. Unit Preventive Maintenance Checks and Services (PMCS) - Continued ITEM TO BE EQUIPMENT NOT ITEM INTERVAL CHECKED OR PROCEDURE READY/AVAILABLE SERVICED Figure 7. Condensate Drains Fresh Air Fresh Air Damper Quarterly 1. Remove top cover (SEC 0018 00). Discharge Damper Actuator Chain inoperative.
  • Page 83 0015 00 Table 1. Unit Preventive Maintenance Checks and Services (PMCS) - Continued ITEM TO BE EQUIPMENT NOT ITEM INTERVAL CHECKED OR PROCEDURE READY/AVAILABLE SERVICED Repair or replace if any defects are found. END OF SECTION 0015 00-8...
  • Page 84 0016 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL MECHANICAL AND ELECTRICAL REPAIRS WARNING Disconnect air conditioner power supply. Maintenance of Mechanical Parts The mechanical maintenance covered in this chapter include: Canvas Cover ............................... SEC 0017 00 Condensate Drain Tube Assembly ........................ SEC 0024 00 Condenser Coil Guard............................SEC 0021 00 Covers and Fresh Air Screen.........................
  • Page 85 0016 00 Use an insulation tester or a multimeter set on a high-resistance range to test for short circuits between the circuit ina component and the outside casing of the component. When testing an electrical component, check for visible damage, and inspect all wiring in the area for damage. END OF SECTION 0016 00-2...

  • Page 86: Canvas Cover - Services

    0017 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL CANVAS COVER – SERVICES REMOVAL, INSPECTION AND CLEANING, INSTALLATION INITIAL SETUP: Personnel Required WARNING Ensure power source is disconnected. REMOVAL 1. Loosen tie strap (4) on the canvas cover (1) (if rolled) and unroll cover. See Figure 1. NOTE Do not leave rolled up when wet.
  • Page 87 0017 00 NOTE Do not roll up immediately after cleaning. Spread canvas cover out flat until it is dry. Figure 1. Canvas Cover REPAIR 1. Repair minor fabric rips, cuts, tears or punctures by applying a patch of duct tape inside surface. 2.

  • Page 88: Covers And Fresh Air Screen - Service

    0018 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL COVERS AND FRESH AIR SCREEN – SERVICE REMOVAL, CLEANING, AND INSTALLATION INITIAL SETUP: Materials/Parts Warm, soapy water Equipment Condition Canvas covered removed (SEC 0017 00) Personnel Required WARNING Ensure power source is disconnected. REMOVAL Top Cover 1.
  • Page 89 0018 00 Access Cover Align access cover (4) and secure with screws (3). Front Top Panel 1. Align top cover (2) and secure with screws (1). 2. Attach canvas cover. See SEC 0017 00. Figure 1. Covers and Fresh Air Screen END OF SECTION 0018 00-2...

  • Page 90: Information Plates Maintenance

    0019 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL INFORMATION PLATES MAINTENANCE REMOVAL AND INSTALLATION INITIAL SETUP: Materials/Parts Warm soapy water Personnel Required Equip m e nt Condition Main power source disconnected WARNING Ensure power source is disconnected. NOTE Remove and replace only badly damaged, unreadable information plates. Refer to SEC 0002 00 for text on each plate or decal.
  • Page 91 0019 00 INSTALLATION Clean area on side of unit where identification plates will be installed with soap and water. Remove protective paper from back of new decals to expose sticky surface. Align decals to proper position and press in place. 4.

  • Page 92: Evaporator Louvers - Service

    0020 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL EVAPORATOR LOUVERS – SERVICE REMOVAL, INSPECTION, CLEANING, AND INSTALLATION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Item 1, Table 2, WP 0083 00) Personnel Required Materials/Parts Cloth, lint free (WP 0085 00) Dry cleaning solvent (Item 16, WP 0085 00) WARNING Ensure power source is disconnected.
  • Page 93 T0020 00 INSPECTION 1. Inspect louver blades for bends or damage and straighten. 2. Inspect evaporator air intake louver and evaporator air discharge louver for other damage. CLEANING 1. Clear obstructions from louver blades using dry cleaning solvent or warm soapy water. 2.

  • Page 94: Condenser Air Discharge Louver Maintenance

    0021 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL CONDENSER AIR DISCHARGE LOUVER MAINTENANCE REMOVAL, CLEANING, AND INSTALLATION INITIAL SETUP: Personnel Required Equipment Condition Canvas cover detached (SEC 001 7 00) Top cover removed (SEC 0018 00) WARNING Ensure power source is disconnected. REMOVAL Condenser Guard Remove condenser guard (1).
  • Page 95 0021 00 Clean with warm soapy water or dry cleaning solvent (Item 16, SEC 0085 00). Figure 1. Air Discharge and Condenser Guard INSTALLATION Condenser Guard 1. Install condenser guard (1). 2. Attach top cover. See SEC 0018 00. 3. Attach canvas cover. See SEC 0017 00. END OF SECTION 0021 00-2...

  • Page 96: Mist Eliminator - Service And Repair

    0022 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL MIST ELIMINATOR – SERVICE AND REPAIR REMOVAL, CLEANING, REPAIR, AND INSTALLATION INITIAL SETUP: Materials/Parts Hose, with running water Personnel Required Equipment Condition Top cover removed (SEC 0018 00) WARNING Ensure power source is disconnected. REMOVAL Slide mist eliminator (1) and filter media (2) up and out of mist eliminator holder brackets (3).
  • Page 97 0022 00 REPAIR Replace bent or damaged mist eliminator. INSTALLATION 1. Insert mist eliminator (1) and filter media (2) into mist eliminator holder brackets (3). NOTE Heed airflow direction arrow on mist eliminator frame. Install cover. See SEC 0018 00. END OF WORK PACKAGE 0022 00-2...

  • Page 98: Evaporator Air Intake Filter - Service/Replace

    0023 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL EVAPORATOR AIR INTAKE FILTER – SERVICE/REPLACE REMOVAL, CLEANING, AND INSTALLATION Materials/ P arts Hose, with running water Personnel Required Equipment Condition Evaporator inlet louver removed (SEC 0019 00) WARNING Ensure power source is disconnected. REMOVAL With the evaporator air intake louver (1) removed, remove evaporator air inlet filter (2) and filter media (3) by sliding the filter and filter media out from either side of louver casing.
  • Page 99 0023 00 CLEANING 1. Inspect filter (2). Replace damaged filter and filter media. Clean with warm soapy water in both directions. 2. Replace filters having breaks, tears, excess accumulations of dirt or grease, or other major damage. INSTALLATION 1. Install evaporator air intake filter (2) and filter media (3) into evaporator air intake louver (1) by sliding the filter and filter media into either side of lover casing.

  • Page 100: Condensate Drain Tube Assembly Maintenance

    0024 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL CONDENSATE DRAIN TUBE ASSEMBLY MAINTENANCE REMOVAL, INSPECTION, CLEANING, AND INSTALLATION INITIAL SETUP: Materials/Parts Water, warm soapy Wire, soft 10-12 gage Bleach and water solution, mild Personnel Required Equipment Condition Top cover removed (SEC 0018 00) Evaporator inlet louver removed (WSEC 0020 00) Mist eliminator removed (SEC 0022 00) WARNING...
  • Page 101 0024 00 Figure 1. Condensate Drain Tube Assembly 3. Install mist eliminator. See SEC 0022-00. 4. Align and install top cover. See SEC 0018 00. 5. Install evaporator inlet louver. See SEC 0020-00. END OF SECTION 0024 00-2...
  • Page 102 0025 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL FRESH AIR DAMPER ASSEMBLY MAINTENANCE REMOVAL, INSPECTION, CLEANING, REPAIR, INSTALLATION, AND TEST INITIAL SETUP: Materials/Parts Cloth, Lint Free Soapy water Personnel Required Equipment Condition Evaporator air intake louver removed (SEC 0020 00) WARNING Ensure power source is disconnected.
  • Page 103 0025 00 Figure 1. Fresh Air Damper Assembly CLEANING Wipe off dirt with clean lint-free cloth moistened with warm soapy water. 0025 00-2...
  • Page 104 0025 00 REPAIR 1. Straighten damper plate (6) and hinge (2) if bent or warped. Replace if necessary. 2. Replace damaged insulation (7). 3. Replace spring (9) if has loose tension. 4. Replace chain (10) if too short. INSTALLATION 1. After replacing defective parts, place ventilation damper into unit housing. 2.

  • Page 106: Remote Control Module Maintenance

    0026 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL REMOTE CONTROL MODULE MAINTENANCE REMOVAL, INSPECTION, TEST, DISASSEMBLY, REPAIR, ASSEMBLY, AND INSTALLATION INITIAL SETUP: Test Equipment Multimeter References Wire List and Schematic Diagram, SEC 0040 00 Personnel Required Equipment Condition Air conditioner shut down and cool. Power disconnected from unit.
  • Page 107 0026 00 Figure 1. Control Module Front Panel 2. Carefully pull remote control module straight out of unit to disconnect connector P3 from J3 in rear of remote control module. See schematic diagram (SEC 0040 00). INSPECTION Temperature Selector Switch S2(15) (Refer to Exploded View Figure 3) 1.
  • Page 108 0026 00 Temperature Selector Switch S2(15) (Refer to Exploded View Figure 3) 1. Turn mode selector switch S1(10) to OFF position. 2. Check for continuity using a multimeter on the lowest ohm setting. Place probes on the connector pins 1 and 12 of connector P3.
  • Page 109 0026 00 Figure 2. Mode Selector Switch DISASSEMBLY (Refer to Exploded View Figure 3) NOTE Disassembly should be limited to the replacement of defective parts. 1. Loosen setscrew on knob (3) and remove knob from mode selector switch (12). 2. Loosen setscrew on knob (4) and remove knob from potentiometer (15). 3.
  • Page 110 0026 00 REPAIR Control Panel 1. Remove dents or deformation, if minor. Replace if major. 2. Replace if marking is illegible. Connector with Leads (20). 1. Inspect wiring for breaks, fraying, discoloration, or damage. Replace if found. 2. Inspect soldered connections for breaks or damage. Repair or replace if found. 3.
  • Page 111 0026 00 4. Install top cover (SEC 0018 00). 5. Reconnect air conditioner to power source. Figure 3. Remote Control Module Exploded View END OF SECTION 0026 00-6...

  • Page 112: Circuit Breaker Maintenance

    WARNING Ensure power source is disconnected. NOTE Work package procedures apply to the three pole circuit breaker assembly (S18K-LW-1 unit). REMOVAL 1. Remove the screws at the front of the control box to remove circuit breaker. 2. Pull out the circuit breaker.
  • Page 113 Circuit Breaker (2) 1. Tag and disconnect leads. 2. On the S18K-LW-1 units, check for continuity in ON position between contacts A1 and B1; A2 and B2; A3 and B3. Continuity should exist. No continuity should exist between these contacts in the OFF position.
  • Page 114 0027 00 INSTALL 1. Place circuit breaker (2) with weatehr boot (5) into position. Connect leads to circuit breaker (2). 2. Secure circuit breaker with screws (4). 0027 00-3...
  • Page 115 0027 00 Figure 1. Circuit Breaker END OF SECTION 0027 00-4...

  • Page 116: Electrical Components Maintenance

    0028 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL ELECTRICAL COMPONENTS MAINTENANCE REMOVAL, INSPECTION, TEST, REPAIR, AND REPLACEMENT INITIAL SETUP Test Equipment Multimeter Variable voltage power source (AC/DC) Personnel Required Equipment Condition Power disconnected from unit. Evaporator air intake louver removed (SEC 0020 00) Top cover removed (SEC 0018 00) Remote control module removed (SEC 0026 00) WARNING...
  • Page 117 0028 00 Figure 1. Temperature Selector Switch Electronic Probe Temperature Selector Switch Electronic Probe (Figure 1) 1. Loosen screw (1) to release electronic probe (4) from clamp (3) on evaporator fan assembly (5). 2. Carefully slide out probe (4) from clamp (3). Junction Box and Lower Housing Plate (Figure 2) 1.
  • Page 118 0028 00 Figure 2. Control Box and Lower Housing Plate Compressor Motor and Condenser Motor Relay (K1), Heater Element Relays (K3), Evaporator Fan Motor Relay (K2). 1. Inspect relays for any external damage to housing. 2. If damaged enough to prevent normal operation of relay, replace relay. Terminal Boards (TB) and Marker Strips 1.
  • Page 119 0028 00 CONNECTOR CONTROL BOX CHASSIS HIGH PRESSURE RESET TOP VIEW BOTTOM VIEW Figure 3. Electrical Components 0028 00-4...
  • Page 120 “pull -in”. 4. Replace if it fails test. Compressor Motor and Condenser Motor Relay (K1), S18K-LW-1 Unit 1. Tag and disconnect wire leads. 2. Use a multimeter and check continuity. Set the lowest ohm to check continuity between terminals L1 to T1, L2 to T2, and L3 to T3.
  • Page 121 0028 00 Evaporator Fan Motor ( K2) and Heater Element Relays ( K3 ) 1. Tag and disconnect wire leads. 2. U se a multimeter and check continuity. Set the lowest ohm to check continuity between terminals L1 to T1. All contacts should be open.
  • Page 122 0028 00 NOTE REPLACEMENT Ensure wire leads are tagged before disconnecting. Compressor Motor and Condenser Motor Relay (K1) (Figure 3) 1. Remove the relay (K1) (1 ) from the junction box. Install replacement relay (K1) (1) on the junction box chassis. Heater Element Relays (K3), Evaporator and Condenser Motor Relay (K2) 1.
  • Page 123 0028 00 Electronic Box Thermostat (Figure 5) 1. With the lower housing plate removed, remove the electronic box thermostat (3) from side of unit housing by removing two screws (1) and lock nuts (2). 2. Remove defective electronic box thermostat (3) and wiring along with connector J2 and probe (4, Figure 1). Figure 5.
  • Page 124 0028 00 3. To remove connector J2 (24, figure 3), remove two screws (22) and two lock nuts (23). 4. Verify wire labels to wire list (SEC 0040 00) and desolder and replace connector J2 (24). 5. Secure connector J2 (24) to junction box chassis (4) with two screws (22) and two lock nuts (23). Junction Box 1.

  • Page 125: Main Power Input Connectors (J1) And (J2) Maintenance

    0029 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL MAIN POWER INPUT CONNECTORS (J1) AND (J2) MAINTENANCE INSPECTION, REMOVAL, TEST, REPAIR, AND INSTALLATION INITIAL SETUP Test Equipment Multimeter Continuity Tester References Wire Lists and Schematic Diagram (SEC 0040 00) Personnel Required Equipment Condition Top cover removed (SEC 0018 00) Circuit breaker assembly partially removed (SEC 0027 00).
  • Page 126 0029 00 Figure 1. J1 Connector NOTE Use Schematic Diagram, SEC 0040 00 for the following instructions. REMOVAL 1. Verify all wire labels and schematics (SEC 0040 00) or tag all wire leads prior to removal. 2. For J1 connector removal, remove one screw and nut that attaches eyelet of J1 cover wire (2). See figure 1. 3.
  • Page 127 0029 00 REPAIR 1. Remove the insulation to expose ½ inch (1.27 cm) of bare wire on each side of break or damaged insulation. 2. Insert the ends into a splice-connector; splice and crimp the connector to make firm electrical contact. 3.

  • Page 129: Transformer Maintenance

    0030 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL TRANSFORMER MAINTENANCE REMOVAL, TEST, AND INSTALLATION INITIAL SETUP: Test Equipment Multimeter Variable voltage power source (AC/DC) References Wire List and Schematic Diagram (SEC 0040 00) Personnel Required Equipment Condition Power disconnected from unit Top covers removed (SEC 0018 00) Junction box partially removed from unit (SEC 0028 00) WARNING...
  • Page 130 0030 00 Figure 1. Transformer Continuity Check INSTALLATION 1. Connect transformer leads and verify wire labels to wire list and schematics (SEC 0040 00). 2. Secure transformer (3) to junction box chassis (4) using two lock nuts (2) and two screws (1). 3.

  • Page 131: Unit Wiring Maintenance

    0031 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL UNIT WIRING MAINTENANCE INSPECTION, TEST, REMOVAL, REPAIR, AND INSTALLATION INITIAL SETUP: Test Equipment Multimeter References Wire list and schematic diagram (SEC 0040 00) Personnel Required Equipment Condition Power disconnected from unit. Top cover removed (SEC 0018 00). Evaporator air intake louver removed (SEC 0020 00).
  • Page 132 0031 00 3. If continuity is not indicated, repair or replace wire or damaged connector. REMOVAL 1. Verify all labels on all wire leads prior to removal. Refer to wire lists (SEC 0040 00). 2. Refer to SEC 0029 00 for connector J2 removal. 3.

  • Page 133: Heater Cutout Switch S3 Maintenance

    0034 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL HEATER CUTOUT SWITCH S3 MAINTENANCE INSPECTION, REMOVAL, TEST, AND INSTALLATION INITIAL SETUP: Test Equipment Multimeter Personnel Required Equipment Condition Power disconnected form unit. Top cover removed (SEC 0018 00) WARNING Ensure power source is disconnected. WARNING Allow heating elements to cool for 15 minutes before touching.
  • Page 134 0034 00 INSTALLATION 1. Attach switch S3 (1) to heater assy. bracket (5) with two lockwashers (3), washers (4) screws (2). 2. Connect leads to switch S3 (1). Refer to wire list and schematic diagram (SEC 0040 00). 3. Install top cover. See SEC 0018 00. Figure 1.

  • Page 135: Evaporator Fan Assembly Maintenance

    0035 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL EVAPORATOR FAN ASSEMBLY MAINTENANCE REMOVAL, DISSEMBLY, INSPECTION, TEST, REASSEMBLY, AND INSTALLATION INITIAL SETUP: Test Equipment Multimeter Continuity Tester References Wire List and Schematic Diagram (SEC 0040 00) Personnel Required Equipment Condition Evaporator inlet louver removed (SEC 0020 00) Condensate drain tubing removed (SEC 0024 00) WARNING Ensure power source is disconnected.
  • Page 136 0035 00 1. Verify labels on motor wiring to wire list (SEC 0040 00) and disconnect the motor wiring. 2. Loosen clamp holding temperature selector switch sensing bulb, move bulb to clear housing. Refer to figure 1, front view illustration. 3.
  • Page 137 0035 00 REASSEMBLY 1. Assemble motor (1) to motor mounting bracket (2). 2. Carefully insert impeller (4) into blower housing (6). 3. Attach inlet rings (7) to each end of blower housing with four lockwashers and screws. 4. Position motor mounting bracket (3) with motor (1). 5.
  • Page 138 0035 00 Figure 2. Evaporator Fan Assembly Exploded View END OF SECTION 0035 00-4...

  • Page 139: Electrical Heater Elements

    0036 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL ELECTRICAL HEATER ELEMENTS MAINTENANCE INSPECTION, TEST, REMOVAL, REPAIR, AND INSTALLATION INITIAL SETUP: Test Equipment Multimeter References Wiring List and Schematic Diagram (SEC 004 0 00) Heater Cutout Switch (SEC 0034 00) Personnel Required Equipment Condition Air conditioner shut down and cool.
  • Page 140 0036 00 TEST 1. Test heater cutout switch S3. See SEC 0034 00. REMOVAL 1. Remove heater cutout switch S3. See SEC 0034 00. 2. Verify wire labels to wiring list (SEC 0040 00). 0036 00-...
  • Page 141 0036 00 ASSEMBLY WARNING 1. Refer to wire lists (SEC 0040 00) and connect leads K3 Install junction box. See SEC 0028 00. 3. Install heater cutout switch S3. See SEC 0034 00. 4. Install top cover. See SEC 0018 00. 0036 00-3...
  • Page 142 0036 00 Figure 1. Electrical Heater END OF SECTION 0036 00-4...

  • Page 143: Wire L Ists And Schematic Diagrams

    0037 00 UNIT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL CONDENSER FAN AND MOTOR MAINTENANCE TEST, REMOVAL, DISASSEMBLY, INSPECTION, ASSEMBLY, AND INSTALLATION INITIAL SETUP: Materials/Parts Grease, General Purpose Test Equipment Multimeter References Wire lists and Schematic Diagram (SEC 0040 00) Personnel Required Equipment Condition Power disconnected from unit.
  • Page 144 0037 3. Remove four fastners from motor mount (1) that secure the motor mounting plate (2) to the motor mount. 4. Slide out motor shaft from shaft extension (2) and fan (3). 5. Lift out motor (2) and mounting plate (1) from unit. 6.
  • Page 145 0037 10. Check to be sure that continuity exists between leads. This means that open circuits do not exist. Replace motor if either open or short circuits exist. ASSEMBLY 1. Install motor (2) on motor mounting plate (1) with four flat washers , and locknuts. INSTALLATION 1.
  • Page 146 0037 Figure 1. Condenser Fan Assembly END OF SECTION 0037 00-4...
  • Page 147 0040 00 Figure 1 Schematic Diagram for the S18K-LW-1 Unit END OF SECTION 0040 00-10/ 0041 00-01...
  • Page 148 CHAPTER 7 DIRECT SUPPORT TROUBLESHOOTING PROCEDURES...

  • Page 150: Direct Support Troubleshooting Introduction

    0042 00 DIRECT SUPPORT TROUB LESHOOTING INTRODUCTION AIR CONDITIONER, COMPACT, HORIZONTAL MALFUNCTION/SYMPTOM INDEX The malfunction/symptom index (SEC 0008 00 and SEC 0043 00) are quick reference indexes for finding troubleshooting procedures. Associated with each symptom name is a work package sequence number representing the starting point in a troubleshooting sequence.

  • Page 152: Direct Support Malfunction/System Index

    0043 00 DIRECT SUPPORT MALFUNCTION/SYSTEM INDEX AIR CONDITIONER, COMPACT, HORIZONTAL TROUBLESHOOTING MALFUNCTION/SYMPTOM PROCEDURE Compressor Will Not Start 1. Control circuit may have an open circuit SEC 0044 00 2. Faulty circuit breaker SEC 0044 00 3. Bad continuity of compressor motor or wiring SEC 0044 00 4.
  • Page 153 0043 00 TROUBLESHOOTING MALFUNCTION/SYMPTOM PROCEDURE 3. Insufficient refrigerant or leaks SEC 0044 00 4. F aulty compressor SEC 0044 00 5. Excess refrigerant SEC 0044 00 Compressor Runs But Does Not Cool 1. Improper power supply SEC 0044 00 2. Excessively high temperature in conditioned area SEC 0044 00 3.
  • Page 154 0043 00 4. Faulty heater cutout switches SEC 0044 00 5. Faulty heater relay SEC 0044 00 6. Bad evaporator fan or motor SEC 0044 00 END OF SECTION 0043 00-3/4 blank...

  • Page 156: Direct Support Troubleshooting Procedures

    0044 00 DIRECT SUPPORT TROUBLESHOOTING PROCEDURES AIR CONDITIONER, COMPACT, HORIZONTAL THIS WORK PACKAGE COVERS: Compressor Will Not Start, Compressor Starts But Stops At Once, Insufficient Cooling, Compressor Runs But Does Not Cool, Compressor Excessively Noisy, Suction Pressure Too Low or Too High, Low Heat or No Heat INITIAL SETUP: Test Equipment Multimeter...
  • Page 157 0044 00 FAULT PROCEDURE 1. COMPRESSOR WILL NOT START - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION COMPRESSOR WILL NOT START Step 4. Check power input plugs (P2 or P1 alternate) using multimeter at TB1 as follows: Replace power input plug which does not pass test. (Refer to SEC 0029 00.) CONNECTOR TERMINAL PLUG PIN...
  • Page 158 0044 00 FAULT PROCEDURE 2. COMPRESSOR STARTS, BUT STOPS AT ONCE OR AFTER SHORT RUN PERIOD Due to Tripped Circuit Breaker MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION COMPRESSOR STARTS, BUT STOPS NOTE When making test for voltage and phase reading, TB1 terminals 4 and 5 are used with P1 alternate plug.
  • Page 159 0044 00 FAULT PROCEDURE 4. COMPRESSOR STARTS, BUT STOPS AT ONCE OR AFTER SHORT RUN PERIOD Due to Tripped High Pressure Switch MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION COMPRESSOR STARTS, BUT STOPS Step 1. Perform pressure testing on system to determine if an overcharge of refrigerant is indicated. See SEC 0055 00.
  • Page 160 Replace defective switch. (Refer to SEC 0026 00 and SEC 0028 00.) Step 2. Refer to schematic diagram (SEC 0040 00) for proper connections. For S18K-LW-1, check electrical rotation of power supply must be A-B-C for proper compressor rotation. Step 3.
  • Page 161 0044 00...
  • Page 162 0044 00 FAULT PROCEDURE 8. LOW HEAT OR NO HEAT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION LOW HEAT OR NO HEAT Step 1. Check heater wiring and control circuit for loose connections or broken wires. Tighten loose connections. Replace or repair broken wires. (Refer to SEC 0026 00, SEC 0028 00, SEC 0034 00, and SEC 0040 00.) Step 2.
  • Page 163 0044 00 FAULT PROCEDURE 11. LOW HEAT OR NO HEAT - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION LOW HEAT OR NO HEAT Step 4. Check continuity of two heater cutout switches at room temperature. Continuity should exist. (Refer to WP 0034 00.) Replace fault switch.
  • Page 164 CHAPTER 8 DIRECT OPERATOR SUPPORT MAINTENANCE INSTRUCTIONS...

  • Page 165: Refrigerant System Description

    0048 00 DIRECT SUPPORT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL REFRIGERANT SYSTEM DESCRIPTION Description WARNING REFRIGERANT-410A (R-410A) Unit contains R-410A, a chemical substance which harms public health and the environment by destroying ozone in the upper atmosphere, and that the equipment is to be serviced by qualified personnel only.
  • Page 166 0048 00 REFRIGERATION SCHEMATIC FO 18K-LW-1 0048 00-2/3 blank...

  • Page 167: Refrigerant System Service - (Discharging)

    0049 00 DIRECT SUPPORT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL REFRIGERANT SYSTEM SERVICE – (DISCHARGING) INITIAL SETUP: Personnel Required Equipment Condition Mode selector switch in OFF position Main power source is disconnected Panels removed (WP 0018 00) Air conditioner removed from shelter, if necessary. Special Environmental Condition WARNING REFRIGERANT (R-410A)
  • Page 168 0049 00 1. Remove screws from service valve access cover. See figure 1. 2. Remove service valve access cover. 3. Unscrew hose connection protective caps from service valves. WARNING REFRIGERANT-R-410A (R-410A) Unit contains R-410A, a chemical substance which harms public health and the environment by destroying ozone in the upper atmosphere, and that the equipment is to be serviced by qualified personnel only.
  • Page 169 0049 00 10. When gas stops flowing, close both service valves. 11. Go to SEC 0050 00 for purging the system. SERVICE VALVES HIGH PRESSURE LOW PRESSURE WITH CAP INSTALLED WITH CAP INSTALLED Figure 1. Discharging Refrigerant Setup END OF SECTION 0049 00-3/4 b l ank...
  • Page 170 0050 00 DIRECT SUPPORT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL REFRIGERANT SYSTEM SERVICE – (PURGING) INITIAL SETUP: Personnel Required Equipment Condition Refrigerant system discharged (WP 0049 00) Main power source is disconnected WARNING Ensure power source is disconnected. WARNING Be sure that the manifold hoses are correctly connected. BLUE Hose = Low Pressure, RED Hose = High Pressure.
  • Page 171 0050 00 SERVICE – PURGING Verify that the system has been discharged using a manifold as described in SEC 0049 00, proceed as follows: 1. See specific component removal/repair instructions. 2. Be sure that refrigerant has been discharged (see SEC 0049 00). 3.
  • Page 172 0050 00 SERVICE VALVES HIGH PRESSURE LOW PRESSURE Figure 1. P u rging S e t u p WITH CAP INSTALLED WITH CAP INSTALLED Figure 1. Purging Setup END OF SECTION 0050 00-3/4 blank...
  • Page 173 0052 00 DIRECT SUPPORT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL REFRIGERANT SYSTEM SERVICE – (LEAK TEST) INITIAL SETUP: Test Equipment Electronic refrigerant gas leak detector Materials/Parts Nitrogen Refrigerant R-410A References SEC 0049 00 Personnel Required Equipment Condition Main power source is disconnected WARNING Ensure power source is disconnected.
  • Page 174 0052 00 1. Refrigerant gas leak detector. If an electronic refrigerant gas leak detector is available, it should be used in accordance with manufacturers recomendations. NOTE The electronic refrigerant gas leak detector is highly sensitive to the presence of a minute quantity of gas in the air, due to this factor, it is quite effective in the detection of a small leak.
  • Page 175 0052 00 CAUTION Connect the refrigerant R-410A cylinder so that only gas will be used for pressurization. d. Open both unit service valves and the charging manifold valves. Open the refrigerant cylinder valve slightly and adjust as necessary to prevent formation of frost, and allow system pressure to build up until the gauges read 40-50 psi (2.8-3.5kg/cm Close the charging manifold valves and the refrigerant cylinder valve.

  • Page 176: Refrigerant System Service - (Evacuation)

    0053 00 DIRECT SUPPORT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL REFRIGERANT SYSTEM SERVICE – (EVACUATION) INITIAL SETUP: Maintenance Level Direct Support Test Equipment Vacuum pump Materials/Parts Nitrogen References Personnel Required Equipment Condition Refrigerant system discharged (SEC 0049 00) Main power source is disconnected WARNING Ensure power source is disconnected.
  • Page 177 0053 00 NOTE SERVICE – EVACUATION 1. Connect the hose from the low pressure service valve to the compound gauge side of the charging manifold. The hose from the high pressure service valve shall be connected to the high pressure gauge side of the charging manifold.
  • Page 178 0053 00 SERVICE VALVES LOW PRESSURE Figure 1. Evacuation Setup HIGH PRESSURE WITH CAP INSTALLED WITH CAP INSTALLED END OF SECTION 0053 00-3/4 blank...

  • Page 179: Refrigerant System Service - (Charging)

    DIRECT SUPPORT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL REFRIGERANT SYSTEM SERVICE – (CHARGING) Maintenance Level Direct Support Test Equipment Charging cylinder or scale Materials/Parts Refrigerant, R-410A References Personnel Required Equipment Condition Refrigerant system evacuated (SEC 0053 00) Main power source is disconnected WARNING Ensure power source is disconnected.
  • Page 180 0054 00 SERVICE – CHARGING 1. Connect the hose from the low pressure service valve to the compound gauge side of the charging manifold. The hose from the high pressure service valve should be connected to the high pressure gauge side of the manifold. See figure 1.
  • Page 181 0054 00 16. Remove charging manifold hoses. 17. Install service valve protective caps. 18. Secure service valve access cover using four screws. SERVICE VALVES Figure 1. Refrigerant Charging Setup HIGH PRESSURE LOW PRESSURE WITH CAP INSTALLED WITH CAP INSTALLED END OF SECTION 0054 00-3/4 blank...

  • Page 182: Refrigerant System Service - (Pressure Testing)

    0055 00 DIRECT SUPPORT MAINTENANCE AIR CONDITIONER, COMPACT, HORIZONTAL REFRIGERANT SYSTEM SERVICE – (PRESSURE TESTING) INITIAL SETUP: Personnel Required Equipment Condition Main power source is disconnected SERVICE – PRESSURE TESTING WARNING Ensure power source is disconnected. WARNING Be sure that the manifold hoses are correctly connected. BLUE Hose = Low Pressure, RED Hose = High Pressure Service Valve Access Cover 1.
  • Page 183 0055 00 6. Compare gauge readings with the normal range of ystem pressure as shown on the Table of Normal Temperaature- Pressure Relationships 7. Disconnect gauges. Install service valve access cover with screws. TABLE 1. Normal Temperature ± Pressure Relationships Pressure Range (PSIG) HIGH PRESSUE LOW PRESSURE...
  • Page 184 CHAPTER 9 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS...
  • Page 185 INDEX Subject SECTION Air Conditioner Operation Under Unusual Conditions..................0006 00 Air Conditioner Operation Under Usual Conditions .................... 0005 00 Canvas Cover – Services ............................ 0017 00 Circuit Breaker Maintenance ..........................0027 00 Condensate Drain Tube Assembly Maintenance....................0024 00 Condenser Fan Assembly Unit Maintenance .......................
  • Page 186 Information Plates Maintenance.......................... 0019 00 Installation Hardware Maintenance........................0041 00 Main Power Input Connectors (J1) Maintenance....................0029 00 Mist Eliminator - Service and Repair........................0022 00 Operator Maintenance Instructions ........................0011 00 Operator Malfunction/Symptom Index........................ 0008 00 Operator Preventive Maintenance Checks and Services (PMCS) ................. 0010 00 Operator Troubleshooting Introduction .......................
  • Page 187 Unit Maintenance Mechanical Repairs and Electrical Repairs................0016 00 Unit Maintenance Service Upon Receipt......................0014 00 Unit Preventive Maintenance Checks and Services (PMCS) ................0015 00 Unit Troubleshooting Introduction........................0012 00 Unit Troubleshooting............................0013 00 Unit Wiring Maintenance ........................... 0031 00 Wire Lists and Schematic Diagrams........................
  • Page 188 18KLW SPARE PARTS LIST SES P/N DESCRIPTION 805-005 BOOT WEATHER C/B 148-101 SCHRAEDER VALVE FITTING 148-102 SCHRAEDER VALVE CORE 305-301 CIRCUIT BREAKER 108-051 COMPRESSOR 136-006 SIGHT GLASS 117-011 FILTER DRIER 156-019 TX VALVE 3/8 X 1/2 900-043 WASHER (COMP MOUNT) 324-013 COND MOTOR 309-023...

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