Service & Parts Manual
2005
Room Air Conditioners
50 & 60 Hz Models
SH15L30-A
SH20L30-A
SH20L50-A
HG-SVC-PRTS-05 (4-05)
3
COMPONENT OPERATION AND TESTING
WARNING
FIGURE 2 COMPRESSOR WINDING TEST
DISCONNECT ELECTRICAL POWER TO THE
UNIT BEFORE SERVICING OR TESTING
COMPRESSORS
Compressors are single phase, 208/230 volt. All
compressor motors are permanent split capacitor
type, using only a running capacitor across the start
and run terminal.
All compressors are internally spring mounted and
externally mounted on rubber isolators.
Testing Procedures
1. Terminal "C" and "S" - no continuity - open
winding - replace compressor.
Line Voltage Overload
The compressor is equipped with an internal line
voltage overload. This overload is embedded in the
windings of the motor to sense the motor temperature.
The overload will open and disconnect the power to the
motor due to high temperatures caused by:
2. Terminal "C" and "R" - no continuity - open
winding - replace compressor.
3. Terminal "R" and "S" - no continuity open
winding - replace compressor.
1. A locked rotor.
2. Excessive running amps.
3. High discharge temperature.
4. Low refrigerant charge.
4. Terminal "C" and the shell of the compressor
– continuity – grounded motor – replace
compressor.
5. Should continuity exist between terminals
"R" and "S", but not between terminals
"C" and "S" and "C" and "R", the internal
overload may be open. If the compressor
is extremely hot, allow it sufficient time to
cool. It may require as long as one hour for
the compressor to cool sufficiently for the
internal overload to close.
FIGURE 1 INTERNAL OVERLOAD
LINE BREAK
INTERNAL OVERLOAD
OHMMETER
COMPRESSOR WINDING TEST (Figure 2.)
Remove the compressor terminal box cover and
disconnect the wires from the terminals. Using an
ohmmeter, check continuity across the following:
4
GROUND TEST
FAN MOTOR (Figure 4)
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.
Use an ohmmeter set on its highest scale. Touch one
lead to the compressor body (clean point of contact,
as a good connection is a must) and the other probe
in turn to each compressor terminal. (See Figure 3.)
If a reading is obtained, the compressor is grounded
and must be replaced.
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.
FIGURE 3 TYPICAL GROUND TEST
FIGURE 4 FAN MOTOR
FAN MOTOR – TEST
Disconnect power to the unit.
CHECKING COMPRESSOR EFFICIENCY
1. Determine that the capacitor is serviceable.
The reason for compressor inefficiency is normally
due to broken or damaged suction and/or discharge
valves, reducing the ability of the compressor to pump
refrigerant gas.
2. Disconnect the black lead from the circuit
board.
3. Apply "live" test cord leads to the common
terminal of the capacitor and the black lead.
The motor should run at high speed.
This condition can be checked as
follows:
SOLID STATE RELAY (Figure 5)
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.
1. Install a piercing valve on the suction and
discharge or liquid process tube.
2. Attach gages to the high and low sides of
the system.
3. Start the system and run a "cooling or
heating performance test."
FIGURE 5 SOLID STATE RELAY
Line side
If test shows:
A. Below normal high side pressure.
B. Above normal low side pressure.
C. Low temperature difference across the coil.
Load side
The compressor valves are faulty
- replace the compressor.
LED indicates
contacts closed
when lit
5
SYSTEM CONTROL SWITCH (Figure 6)
This switch is double pole, single throw. Check for
continuity between terminals 2 and 3, and 5 and 6.
CAPACITOR – TEST
1. Remove the capacitor from the unit.
2. Check for visual damage such as bulges, cracks,
or leaks.
3. For dual rated capacitors, apply an ohmmeter lead
to the common (C) terminal and the other probe to
the compressor (HERM) terminal. A satisfactory
capacitor will cause a deflection on the pointer,
then gradually move back to infinity.
FIGURE 6 SWITCH, ON-OFF
4. Reverse the leads of the probe and momentarily
touch the capacitor terminals. The deflection of the
pointer should be two times that of the first check
if the capacitor is good.
5. Repeat steps 3 and 4 to check the fan motor
capacitor.
CAPACITOR, RUN
NOTE: A shorted capacitor will indicate a low
resistance and the pointer will move more to the
“0” end of the scale and remain there as long as
the probes are connected. An open capacitor
will show no movement of the pointer when
placed across the terminals of the capacitor.
A run capacitor is wired across the auxiliary and main
winding of a single phase permanent split capacitor
motor such as the compressor and fan motors. A single
capacitor can be used for each motor or a dual rated
capacitor can be used for both.
The capacitor’s primary function is to reduce the
line current while greatly improving the torque
characteristics of a motor. The capacitor also reduces
the line current to the motor by improving the power
factor of the load. The line side of the capacitor is
marked with a red dot and is wired to the line side of
the circuit (see Figure 7.)
THERMOSTAT
A cross ambient
thermostat is used to
maintain the desired
comfort level. The
thermostat reacts only to
change in temperature at
bulb location.
FIGURE 7 RUN CAPACITOR HOOK–UP
Important to the
successful operation
of the unit is the position
of the sensing bulb in
relation to the evaporator
COMPRESSOR
FAN
MOTOR
(see Figure 8).
FIGURE 8 SENSING
BULB LOCATION
RED DOT
RANGE:
Thermostat
(Part No. 618-225-02)
60° F ( 2° ) to 90° F( 4° )
RUN CAPACITOR
6
TEST
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.
7
LOW AMBIENT BYPASS VALVE (Figure 9)
SEALED REFRIGERATION SYSTEM
REPAIRS
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 50 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.
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 (G.E. Type
H-6 or equivalent).
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 50 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.
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 - (0-400 lbs.)
10. Low Pressure Gauge - (30" - 150 lbs.)
11. Vacuum Gauge - (0-1000 microns)
FIGURE 9
LOW AMBIENT Bypass
VALVE
EQUIPMENT MUST BE CAPABLE OF:
1. Recovering CFC’s as low as 5%.
2. Evacuation from both the high side and low side
of the system simultaneously.
3. Introducing refrigerant charge into the high side of
the system.
4. Accurately weighing the refrigerant charge actually
introduced into the system.
5. Facilities for flowing nitrogen through the
refrigeration tubing during all brazing processes.
8
HERMETIC COMPONENT REPLACEMENT
NOTE: This procedure can be sped up by the
use of heat lamps, or by breaking the vacuum
with refrigerant or dry nitrogen at 5,000 microns.
Pressure system to 5 PSIG and leave in the sys-
tem a minimum of 10 minutes. Recover refriger-
ant, and proceed with evacuation to a pressure
of 200 microns or a minimum of 10%.
The following procedure applies when replacing
components in the sealed refrigeration circuit or
repairing refrigerant leaks. (Compressor, condenser,
evaporator, capillary tube, refrigerant leaks, etc.)
1. Recover the refrigerant from the system at the
process tube located on the high side of the system
by installing a line tap on the process tube. Apply
the gauge from the process tube to EPA approved
gauges from the process tube to the EPA approved
recovery system. Recover the CFC’s in the system
to at least 5%.
11. Break the vacuum by charging the system from
the high side with the correct amount of refrigerant
specified. This will prevent boiling the oil out of the
crankcase.
2. Cut the process tube below the pinch off in the
suction side of the compressor.
NOTE: If the entire charge will not enter the high
side, allow the remainder to enter the low side
in small increments while operating the unit.
3. Connect the line from the nitrogen tank to the
suction process tube.
4. Drift dry nitrogen through the system and unsolder
the more distant connection first. (Filter drier, high
side process tube, etc.)
12. Restart the unit several times after allowing
pressures to stabilize. Pinch off the process tubes,
cut and solder the ends. Remove the pinch off tool,
and leak check the process tube ends.
5. Replace the inoperative component, and always
install a new filter drier. Drift dry nitrogen through
the system when making these connections.
SPECIAL PROCEDURES IN THE CASE OF
COMPRESSOR MOTOR BURNOUT
1. Recover all refrigerant and oil from the system.
6. Pressurize the system to 30 PSIG with proper
refrigerant and boost the refrigerant pressure to
150 PSIG with dry nitrogen.
2. Remove the compressor, capillary tube and filter
drier from the system.
7. Leak test the complete system with the electric
halogen leak detector, correcting any leaks
found.
3. Flush the evaporator, condenser and all connecting
tubing with dry nitrogen, or equivalent, to remove all
contamination from the system. Inspect the suction
and discharge lines for carbon deposits. Remove
and clean if necessary.
8. Reduce the system to zero gauge pressure.
9. Connect the vacuum pump to the high side and
low side of the system with deep vacuum hoses,
or copper tubing. (Do not use regular hoses.)
4. Reassemble the system, including a new drier-
strainer and capillary tube.
10. Evacuate the system to an absolute holding
pressure of 200 microns or less.
5. Proceed with processing as outlined under hermetic
component replacement.
9
ROTARY COMPRESSOR SPECIAL
TROUBLESHOOTING AND SERVICE
Basically, troubleshooting and servicing rotary com-
pressors is the same as on the reciprocating compres-
sor with only a few exceptions.
REFRIGERANT CHARGE
1. The refrigerant charge is extremely critical. Measure
the charge carefully and as exactly as possible to
the nameplate charge.
2. The correct method for charging the rotary is to
introduce liquid refrigerant into the high side of the
system with the unit off. Then start the compressor
and enter the balance of the charge, gas only, into
the low side.
1. Because of the spinning motion of the rotary, the
mounts are critical. If vibration is present, check
the mounts carefully.
2. The electrical terminals on the rotary are in a
different order than the reciprocating compressors.
The terminal markings are on the cover gasket.
Use your wiring diagram to insure the correct
connections.
The introduction of liquid into the low side, without
the use of a capillary tube, will cause damage to
the discharge valve of the rotary compressor.
NOTE:
AllinoperativecompressorsreturnedtoFriedrich
must have all lines properly plugged with the
plugs from the replacement compressor.
10
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
Power disconnected.
TO CORRECT
Check power source.
System switch in “Off”
position.
Set switch correctly.
Replace fuse, reset breaker. If repeats, check fuse
or breaker size. Check for shorts in unit wiring and
components.
Branch circuit fuse blown or
circuit breaker tripped.
UNIT DOES NOT RUN.
Inoperative system switch.
Test for continuity.
Loose or disconnected wiring Check wiring and connections.
at switch. Connect per wiring diagram.
Inoperative switch (On-Off). Test for continuity, 3 and 2, 5 and 6.
Dirty Filter.
Clean as recommended in Owner’s Manual.
Check for dirty or obstructed coil - clean as required.
Test for shorted thermostat or stuck contacts.
De-ice coil and check for leak.
Restricted air flow.
Inoperative thermostat.
Short of refrigerant.
EVAPORATOR COIL
FREEZES UP.
De-ice coil. Check temperature differential across coil.
Touch test coil return bends for same temperature. Test for
low running current.
Partially restricted capillary.
Inoperative fan motor.
Test and replace if inoperative.
Excessive heat load.
Restriction in line.
Test cooling performance of unit. Unit undersized.
Check for partially iced coil. Check temperature split
across coil.
Check for presence of oil on silver soldered connections.
Check for partially iced coil. Check split across coil.
Check for low running amperage.
COMPRESSOR RUNS
CONTINUALLY.
Refrigerant leak.
DOES NOT CYCLE
OFF.
Check operation of thermostat. Replace if contacts
remain closed.
Thermostat contacts stuck.
Loss of charge in thermostat Place jumper across thermostat terminals. If unit
bulb.
operates, replace thermostat.
Loose or broken parts in
thermostat.
THERMOSTAT DOES
NOT TURN UNIT ON.
Check as above.
Incorrect wiring.
Connect per wiring diagram.
System switch open.
Test for continuity at switch terminals 2 and 3.
Thermostat set at coldest
point
Turn to highest temperature setting to see of unit will cycle
off.
THERMOSTAT DOES
NOT TURN UNIT OFF.
Disconnect power to the unit. Remove cover of thermostat
and check if contact is stuck, if so replace thermostat.
Test switch for open contacts at terminals 2 and 3 with
switch in “Off” position.
Thermostat contacts stuck.
Switch (On - Off) shorted.
11
TROUBLESHOOTING (Continued)
PROBLEM
POSSIBLE CAUSE
Compressor attempts to start
before system pressures are
equalized.
TO CORRECT
Allow a minimum of two (2) minutes to allow pressures to
equalize before attempting to start.
Check voltage with unit operating. Check for other
appliances on the circuit. Unit should be on separate
circuit for proper voltage, and be fused separately.
Connect per wiring diagram.
Check by substituting a known good capacitor of correct
rating.
Low or fluctuating voltage.
COMPRESSOR
ATTEMPTS TO
START, OR RUNS
FOR SHORT
Incorrect wiring.
Shorted or incorrect capacitor.
PERIODS ONLY.
CYCLES ON
OVERLOAD.
Restricted or low air flow through
condenser coil.
Check for proper fan speed or blocked condenser.
Compressor running abnormally Check for kinked discharge line or restricted condenser.
hot.
Check amperage.
Change compressor if all other corrections above are
normal.
Overload opens too soon.
Check continuity of thermostat at coldest setting. Jump
contacts, if compressor runs, replace thermostat.
Thermostat contacts not closing.
Low voltage supply.
Switch (On-Off) inoperative.
Check for nameplate voltage.
Test for continuity.
COMPRESSOR
DOES NOT START -
FAN MOTOR RUNS.
Check by substituting a known good capacitor of correct
rating.
Check voltage at compressor terminals. If voltage is
satisfactory, replace compressor.
Open capacitor.
Internal overload open.
Relay open
Replace relay
Open or shorted compressor
windings
Check windings for continuity and resistance. Direct test
compressor. If direct test fails, replace compressor.
Set to coldest position. Test thermostat and replace if
necessary.
Clean as recommended in Owner’s Manual.
Thermostat open or inoperative.
Dirty air filter.
Dirty or plugged condenser or
evaporator coil.
Poor air circulation in area being
cooled.
Use steam or detergents to clean.
DOES NOT COOL,
OR COOLS ONLY
SLIGHTLY.
Adjust air louvers.
Low capacity - undercharge.
Clean, check for leak and make repair.
Compressor not pumping
properly.
Check amperage draw against nameplate. If not
conclusive, make pressure test.
12
TROUBLESHOOTING (Continued)
PROBLEM
POSSIBLE CAUSE
Defective switch (On-Off).
TO CORRECT
Check continuity across terminals 2 and 3.
Check by substituting a known good capacitor of the
same rating.
Fan capacitor open.
Inoperative fan motor.
Incorrect wiring of fan circuit.
Relay open.
Direct test fan motor.
Connect per wiring diagram.
Replace Relay.
FAN MOTOR DOES
NOT RUN.
Check for seized motor bearings. Rotate by hand, add oil, if noisy, replace.
Bound fan blade or blower wheel. Adjust for proper clearance.
SWITCH (ON-OFF)
DOES NOT CUT
FAN MOTOR OFF.
Selector Switch Relay
Replace selector switch. Replace relay.
Poor installation.
Refer to Installation Instructions for proper installation.
Adjust motor mount to attain proper fan blade and
blower wheel clearance.
Fan blade striking chassis.
NOISY AND/OR
VIBRATION.
Check for deteriorated compressor grommets, or
missing mounting parts.
Compressor vibrating.
Loose cabinet parts, improperly
mounted components, tubing
rubbing.
Adjust and tighten as required.
Evaporator drain pan
overflowing.
Clean obstructed drain trough.
WATER LEAKS
INTO ROOM.
Condensation forming on bottom Evaporator drain pan broken or cracked. Reseal or
of base pan.
replace.
Water dripping from discharge
air grilles.
Dirty evaporator coil, or extremely high humidity
conditions. Clean coil with steam or detergent.
Evaporator drain pan cracked or
obstructed.
Repair and clean, or replace as required.
Remove condenser shroud, Clean and remove old
sealer from base pan and shroud. Apply new sealer,
reinstall and check.
Water in center section of base
pan (compressor area).
OUTSIDE WATER
LEAKS.
Dirty Condenser coil.
Clean with steam or detergent.
Fan blade and slinger ring
improperly positioned.
Adjust fan blade to 1/2" clearance from condenser coil.
13
WIRING DIAGRAM
MODELS SH15L30-A, SH20L30-A, SH20L50-A
14
HAZARDGARD CABINET PARTS
15
HAZARDGARD CHASSIS PARTS
16
HAZARDGARD PARTS LIST
REF
DESCRIPTION
PART NO#
MODELS
CODE
ELECTRICAL PARTS
1
1
1
2
2
2
5
*
COMPRESSOR
COMPRESSOR
COMPRESSOR
MOTOR, FAN
MOTOR, FAN
MOTOR, FAN
61193549
61193550
61193565
61871426
61871427
61871450
60935300
61829700
61108800
61825502
61080546
61080547
61821308
1
1
600
600
600
110
110
110
130
399
399
120
150
150
399
1
1
1
1
1
1
2
1
1
1
1
SWITCH, ON-OFF DPST
INSULATOR, ELECTRICAL
RELAY, SOLID STATE
THERMOSTAT
1
1
2
1
1
1
1
1
1
2
1
1
1
1
*
6
7
7
*
CAPACITOR 20/7.5 440 V.
CAPACITOR 25/7.5 440 V
HARNESS, WIRE, COMP.
REF
DESCRIPTION
PART NO#
MODELS
CODE
REFRIGERATION PARTS
9
9
EVAPORATOR COIL
61850100
61850001
62050400
62050401
60308101
01390005
03760518
60809500
1
1
400
400
410
410
480
471
471
520
EVAPORATOR COIL
CONDENSER COIL
CONDENSER COIL
DRIER, LIQUID
1
1
10
10
*
1
1
1
1
1
1
CAPILLARY TUBE
CAPILLARY TUBE
VALVE, BY-PASS
2
1
2
1
1
17
HAZARDGARD PARTS LIST
REF
DESCRIPTION
PART NO#
MODELS
CODE
CHASSIS PARTS
26
26
27
22
22
23
23
30
30
29
29
35
17
11
37
37
*
SHROUD, CONDENSER
61803601
61804901
61802600
60542003
60542004
60610616
60610617
61814905
61817505
61817300
61817400
61831005
61822602
61493905
61808905
61811110
61989000
60865808
60865809
61823000
61829800
61802500
61804100
61803414
61803800
91400400
01193549
61825703
61825704
61803800
61818801
61819701
61819801
60294408
60294409
60846016
61717301
1
720
720
722
710
710
700
700
743
743
742
742
753
760
761
772
772
752
754
754
756
999
900
900
730
840
791
790
770
770
771
771
999
999
999
999
999
780
SHROUD, CONDENSER
BRACE, COND.SHROUD
FAN BLADE, COND.
FAN BLADE, COND.
BLOWER WHEEL, EVAP.
BLOWER WHEEL, EVAP.
SCROLL
1
3
1
3
3
1
1
1
1
1
1
1
1
1
1
SCROLL
BLOWER FRONT
BLOWER FRONT
PLENUM ASSEMBLY
DECORATIVE PANEL
KNOB, CONTROL
GRILLE, INTAKE
1
1
1
1
1
1
1
1
1
1
1
1
GRILLE, INTAKE
1
2
1
2
LATCH, INTAKE GRILLE
FILTER, AIR
2
1
*
*
FILTER, AIR
1
2
1
1
2
1
*
HOLDER, FILTER
HOLDER, THERMOSTAT
FAN MOTOR MOUNT
FAN MOTOR MOUNT
BASE PAN
2
1
1
8
25
25
32
*
1
1
1
3
3
1
1
1
3
3
1
1
3
3
1
DRAIN PAN, EVAP.
BOLT, COMP. MOUNT
GROMMET, COMP. MOUNT
OUTER SHELL
34
,
36
36
*
OUTER SHELL
1
1
REAR GRILLE
1
*
REAR GRILLE
1
1
2
1
1
2
40
41
38
38
*
ANGLE, WINGBOARD TOP
ANGLE,WINGBORD SIDE
WINGBOARD
1
2
1
WINGBOARD
1
1
1
1
1
1
BAG, ASSY. HARDWARE
GASKET, CHASSIS
1
1
*
OPTIONAL ACCESSORY ITEMS
*
*
DRAIN KIT, DC-2
01900235
01900312
1
1
1
1
1
1
START KIT, CAP.\RELAY
18
19
Use Factory Certified Parts.
FRIEDRICH AIR CONDITIONING CO.
Post Office Box 1540 · San Antonio, Texas 78295-1540
4200 N. Pan Am Expressway · San Antonio, Texas 78218-5212
(210) 357-4400 · FAX (210) 357-4480
HG-SVC-PRTS-05 (4-05)
Printed in the U.S.A.
|