service manual for 6636 series two ton high efficiency
Contents
1. RV Products A Divi RXCFEI ag SERVICE MANUAL FOR 6636 SERIES TWO TON HIGH EFFICIENCY PACKAGED AIR CONDITIONERS TABLE OF CONTENTS 1 Warnings amp Component 2 2 Unit 3 3 Thermostat Operation amp 4 4 Thermostat 5 5 Unit Depiction 5 6 Wiring Diagrams Electronic Thermostat amp A C Unit 0 ccc eee cee ee eee 7 7 Wirebox Component 9 8 Indoor Blower Motor 1 10 9 Outdoor Blower Motor 1 12 10 Cap Tube 13 1 Evaporator Coil 14 12 Condenser Coil 15 13 Compressor 15 14 Electrical Flow 16 1 WARNINGS IMPORTAN2. and control wiring can be quickly attached plugged in to the thermostat 2 UNIT SPECIFICATIONS pz MODELNUMBEKR SERIAL NUMBER FOR OUTDOOR USE UP 6636 345 ELECTRICAL RATINGS LIS VAC 60 17 1PIIASE COMPRESSOR 1450A211 MOTOR THERMALLY PROTECTED BLOWER MOTOR DATA 15 RLOWER MOTOR DATA 1 5 AMP MINIMUM CIRCUIT CAPACITY 90 AMP MAXTMIIM OVERCIERRENT PROTECTIVE DEVICE gt OZ R 22 CHARGE WEIGHT MIN SUPPLY CONDUCTOR GAUGE 94 40 COPPER p UTILISER DES FILS D ALIMENTATION EN 4U 63 CURVE 0 WEIGHT LENGTII DEPTH RV PRODUCTS A DIVISION OF AIRXCEL INC WICHITA 67204 3 THERMOSTAT OPERATION AND SPECIFICATIONS THERMOSTAT OPERATING AND WIRING Should the installer desire to hard wire this connection rather REQUIREMENTS than purchasing the receptacle the three pin connector can be cut from the wire ends the wires stripped and spliced to The 6636 series air conditioner is designed to be operated from complete the required connections For further wire an RV Products electronic wall mounted thermostat See identification and function reference Chart 2 component match up sheet for thermostat part number and description The thermostat is designed to operate 12 VDC CHART 2 controlled heating and air conditioning systems The thermostat is designed to operate 12 VDC controlled heating WIRE FUNCTION
3. 115 VAC to System 1 T1 amp T5 p c board 0 K 12 VDC to GH amp B at ND Check 12 VDC to Restore 12 VDC thermostat R amp B at thermostat B 4 0 K K Replace thermostat 12 VDC to pin connectors GH amp B NO ph p c board See Figure 14 Check all pin connectors and connection from thermostat Replace lifeline if necessary 115 VAC to contact NO pn relay 4 and T5 Replace he board p c board See Figure 13 Check wiring to motor NO Reconnect wiring or Check capacitor and motor replace or windings for open or motor if necessary ground COMPRESSOR 1 CHECKOUT THERMOSTAT CALLING FOR COMPRESSOR Note All operating functions subject to thermostat time delays 115 to system 91 alep NO Io Tl amp T5 on p c board K 12 VDC to amp on thermostat NO SIRO ean Ra member lime delays 26 Minufy 0 K NO Check 12 VDC to lisse aE R amp B on Reatore 12 VDC Check all inal thermostat 17 VDC pin ennnectors YER and connectors to p c beard T2 amp thermostat Replace See Figure 14 0 lifeline if necessary K 0 NO 115 VAC to K Mb Restore 115 VAC K Green I F D Light On Replace relay if 12 Freeze sensor f VDC Is and NO Check compressor 1 closed rator to Tree Ze or if relay welded 0 0 K Ch
4. BREAKDOWN FOLLOWS 6 6 3 6 Sub Mounted Unit 24 000 BTU High Non Exhaust Efficiency 8 7 1 12 VDC Control Tecumseh Compressor PTCR Start Capacitor FIGURE 1 6 WIRING DIAGRAMS Diagram 1976G119 Electronic Wall Thermostat Assembly 12 VDC FAN SWITCH HI AUTO LO SYSTEM SWITCH Ist STAGE COOL A 6636 3451 FAN WALL THERMOSTAT S ASSEMBLY oo gt 2nd STAGE COOL 30 SEC DELAY ON TO FURNACE 679584551 LIFELINE PAINTED CIRCUIT CONTROL BOARU CIRCUIT 2 CIRCUIT 1 THERMISTOR FREEZE SWITCH COMPRESSOR 2 START DEVICE COMPR a e Sus s d 5455 8888 x v sou QAO INDOOR QuTUODR BLOWER _BRN WHT CAPACITOR 2 COMPRESSOR RELAY c 1 COMPRESSOR 12 5 370 V SHOWN BOLD SHOWN FINE HOWN DASHED 115 PER N LOW VOLT WIR BOARD CIRCU NOTE HIGH VOLT WIRII P C IDENTIFIED TERMINAL Green F D Indicator System 1 Ine power DK Freeze swilch is closed 12 VDC fram thermostat OK K4 Excluslon relay energized from System 71 115V power closes FF clreuh to thermostat unless freeze switch 16 Indoor Blower High K5 1 coil 1 pole relay energized fram GH on the thermostat makes Circuit 1 to high speed motor tap T2 12 VBC from Y1 thermostat 10 Comp 1 r
5. E D low speed See Figure 13 Line volts 115 to terminal T4 amp T5 on p c Refer to compressor board L1 line power from 1 checkout compressor 1 relay 115 VAC to T11 amp T13 on p c board Replace p c board Check wiring to O D blower Rewire to motor or Check capacitor Check replace components motor for ground or open as necessary 22 CHECKOUT OUTDOOR BLOWER HIGH SPEED Outdoor blower system 2 red L E D 3 high 7 See Figure 13 Line volts 115 VAC to terminal TB amp T9 on p c board L1 line NO power from compressor 2 relay 115 VAC to T12 amp T13 NO on p c board Replace p c board Remove O D motor leads Red 0 K 0 K amp black wires from p c board and check p c board for 115 Check fuse on motor black Bad Fuse VAC to both motor speede at the wire if equipped time T12 amp T13 High Speed T11 amp T13 Low Speed If No Fuse Replace fuse if only T12 amp T13 high speeds are energized high amp low speeds are powered from the p c board Check wiring to O D blower Check capacitor Check motor for open Dr Rewire to motor or replace components as necessary 23 1976C294 8 05 PP RV Products A Nivi nt RXCFEI ag RV Products A Division of Airxcel Inc P O Box 4020 Wichita KS 67204
6. AMP part numbers are wirebox printed circuit board Insure that the plug snap locks into the receptacle 1 3 pin male receptacle 7 480700 0 2 female pin for male receptacle 350218 1 Routing of the thermostat wiring harness must comply with all local and national electrical codes Collect any excess thermostat harness in the air conditioner mounting compartment Be sure to secure the excess wiring within the compartment Coiling the excess harness into 3 diameter circles or larger is acceptable THERMOSTAT MOUNTING Follow the instructions packed with the thermostat to select a location for thermostat mounting Pay particular attention to choose a location which is not isolated from air currents and not subject to direct discharge from a cold air register Included in the thermostat installation instructions is a mounting template to aid in the installation IMPORTANT To reduce the potential for thermostat failure always connect the 12 VDC supply lead to the BLUE wire in the thermostat 3 pin receptacle before removing anti static protective covering This will ensure that the thermostat circuitry is not damaged by static electricity during installation 4 THERMOSTAT CHECKOUT 1 Before engaging power to any system ensure following A tools have been removed from the equipment B wiring is attached routed and properly secured C panels both mechanical and electrical are
7. T NOTICE WARNING SHOCK HAZARD These instructions are for the use of qualified individuals To prevent the possibility of severe personal injury or specially trained and experienced in installation of this type equipment damage due to electrical shock always be sure the equipment and related system components electrical power to the appliance is disconnected Installation and service personnel are required by some states CAREFULLY FOLLOW ALL INSTRUCTIONS AND to be licensed PERSONS NOT QUALIFIED SHALL NOT WARNINGS IN THIS BOOKLET TO AVOID DAMAGE TO INSTALL NOR SERVICE THIS EQUIPMENT THE EQUIPMENT PERSONAL INJURY OR FIRE NOTE WARNING The words Shall or Must indicate a Improper installation may damage equipment can create a requirement which is essential to satisfactory hazard and will void the warranty and safe product performance The use of components not tested in combination with these The words Should or May indicate a units will void the warranty may make the equipment in recommendation or advice which is not violation of state codes may create a hazard and may ruin the essential and not required but which may equipment be useful or helpful COMPONENT MATCH UP 1 6636 Series Package Air Conditioner Reference 2 6636 Series Electronic 12 VDC Wall Mounted specifications for model number breakdown and Thermostat This thermostat is pre wired to two identification electrical connectors Both the thermostat supply
8. and air conditioning systems The thermostat must be COLOR each wire connecte with operated from a 12 VDC power source 12 VDC Supply Lead The thermostat can control one stage heating and two stages BLUE 12 VDC Supply Lead of cooling The thermostat used to operate the 6636 series air WHITE Furnace Control Wize engager furnace conditioner must be capable of controlling two stage cooling Furnace Control Wire engages furnace systems IMPORTANT Maximum thermostat output for any load including the furnace control wire must not exceed one amp When using wire nuts to complete electrical connections always apply a U L approved electricians tape and secure the IMPORTANT wire nuts to the wires in a workmanlike manner Current draws in excess of one amp or THERMOSTAT HARNESS shorting any thermostat wires will cause permanent thermostat failure RV Products produces a pre wired 35 thermostat wiring harness for this system See component match up sheet for The installer must provide the power source used to operate harness part number and description This harness consists both the thermostat and its control circuits This power of the eight wires required for operating the air conditioner and source must provide one amp of continuous current at 12 quick connect receptacles for both the thermostat and the air VDC conditioner connections The thermostat is pre wired at RV Products with two quick At the thermostat the connection is complete
9. ay high epaod Supply Grounded lerminal F Freeze Switch amp Exclusion Relay Cooling Compressor 2 Compressor 1 FY Freeze Switch amp Exclusion Relay FIGURE 14 Plug positions on the p c board If no voltage is detected at the p c board connector check for voltage at the thermostat All functions of this air conditioning unit are subject to thermostat time delays according to the operation manual 8 INDOOR BLOWER MOTOR REMOVAL Remove indoor blower access panel Disconnect wiring from motor terminal block and capacitor Remove 4 screws from venturi See 1 Figure 7 Remove 3 screws from motor mount bracket See 2 Figure 7 10 Remove motor assembly from scroll Remove blower wheel and motor mounting bracket Note Upon reassembly the references made on Figures 7 and 8 shall be used for proper reassembly Section 1 Section 2 Section 3 SIDE VIEW x4 Scelion FIGURE 7 Position motor with terminal block parallel to Section 4 Motor rotation wires to be connected motor mount clamp Assemble motor mount Yellow to Yellow and Orange to Orange into scroll in orientation shown Section 5 Bundle the rotation and capacitor wires up Torque nut to 65 in 16 min and wire tie together Ground wire terminal assemblies between screw head and washer END VIEW FIGURE 8 1 Wheel must be mounted with a minimum of 5 16 clearance to scroll sides 2 Apply grease
10. cap tube assembly assemblies from points See 1 and 2 Figure 12 Make note of plumbing and cap tube locations the replacement tubes will have to go back to the same locations Cut wire ties holding cap tube assemblies to other plumbing and remove assembly Note Upon reassembly the references made on Figures 11 and 12 shall be used for proper reassembly The assemblies shall be secured with wire ties in order to prevent excess chafing and vibration FIGURE 11 13 11 EVAPORATOR COIL REPLACEMENT Remove top and side panels next to evaporator 5 Remove screws 4 5 6 Figure 12 Remove refrigerant charge from both systems 6 Upon reassembly the references made on Figure 12 shall be used for proper reassembly Unbraze joints 1 and 3 Figure 12 Remove freeze sensor in evaporator coil 14 12 CONDENSER COIL REPLACEMENT Remove top panel Remove screws along wirebox side of coil See 7 Figure 12 Remove corner panel See Figure 12 Be certain at this point that the refrigerant charge has been removed from the systems Make note of plumbing locations The plumbing will have to go back to the same locations on the new coil Unbraze discharge and liquid lines at points 42 and 9 Figure 12 Remove condenser coil 13 COMPRESSOR REPLACEMENT Remove compressor access panel The top panel may be removed at this point if it allows technicians better access to perform service Remove
11. d with a square 9 connect electrical receptacles There is one 9 pin receptacle pin receptacle that slides together and snap locks in place carrying the 8 control wires required to operate the air When making this connection conditioner and a 3 pin receptacle carrying the two power supply leads and the one furnace control lead 1 verify that the connectors are properly aligned The thermostats 9 pin receptacle mates with a receptacle on one end of the RV Products 35 pre wired thermostat harness 2 do not use excessive force when joining the See component match up sheet for harness part number and connectors description 3 verify that the connectors have snapped The thermostat 3 pin receptacle has no mate in either the together on both sides thermostat harness wiring or the thermostat package Should the installer desire a total plug in system then the mate for this The thermostat umbilical attaches to the unit with a rain tight connection will have to be purchased separately Both the fitting To install remove the ring nut from the rain tight receptacle and the pins are manufactured by AMP Aircraft fitting and insert the wire end and fitting into the hole in the Marine Products Inc Harrisburg PA In most cases the wirebox side The ring nut will now slide over the wire end parts can be obtained through a local supply house and reinstall onto the rain tight fitting threads Tighten securely The wire end plugs into the receptacle on the The
12. eck pin lerminals and all Check compressor 1 start connections from thermostat to p c Heepnnect wires device Che AE TOT proper wiring board Check 12 VDC to R amp B at p c or replace ip compressor Check board Sce Flgure 14 components as compressor run capacitor necessary Check motor windings Tor open nr ground Everything ahove checks oul replace p c board 20 COMPRESSOR 2 CHECKOUT THERMOSTAT CALLING STAGE 2 COOLING ONLY Note Operating Functions Subject To Thermostat Time Delays Check 115 VAC to system NO Restore 115 VAC 2 to compressor 2 relay and common 2 Replace thermostat if system NO 2 should be callin andit not 12 VDC to Y2 amp B at thermostat according to operation manual K NO See compressor 1 System 1 compressor operating checkout 0 K K 12 VDC to pin connectors NO Check all pin terminals and 2 amp on p c board Also connections from thermostat Replace lifeline if necessary T10 amp T3B See Figure 14 0 K Check compressor 2 NO Replace relay if 12 VDC is relay operation present and relay won t close or if relay is welded 0 K Check compressor start device Check for proper wiring to NO compressor 2 Check compressor Reconnect wiring or replace components as necessary run capacitor Check compressor motor windings for open or ground 21 CHECKOUT OUTDOOR BLOWER LOW SPEED Outdoor blower system 1 red L
13. elay TAB 12 VbC from B thermostal 10 12 VBC from on thermostat 10 Comp 2 relay Sae blower Low 12 VDC coil 1 pole relay energized from BL on the thermostat Circuit 1 to low epeed motor fap Supply Grounded Terminal 7 WIREBOX COMPONENT CHECKOUT HGURL 13 Switching Relay Switches blower to high epeed with Comp 2 operation T4 Q N D T9 Energize blower high speed relay and switching relay power comes 11 System 1 power L to indoor blower io high and low lso power fo exclusion ralay JA from comp 72 relay light indicates System blower running on B AI pp EA 113 115V L2 power laad oulpul 10 Q D blower high or low speed 115V line L1 power oulpul to blower relay high speed BLACK WHITE BLACK WHITE CIRGUIT 1 CIACUIT 2 12 coil makes Circuit 1 to Comp 1 1 VIE coll makes Clreult 82 to Comp 2 Red light indicates 0 0 blower operation low speed 1 L1 Powar Irom Syelem 41 comp Energizee 0 0 blower relay low speed on term board T5 Syelam 1 common lead L2 to O D blower relay low specd through normally closed contactor on switching relay System 2 common L2 power Ip ewilching relay and D D blower ral
14. in place D The thermostat system switch is placed into the OFF position E co workers have been warned that the equipment is being energized 2 System wiring may be checked by referring to the wiring diagram located on either the back of the wiring box door or the back of the manual The wiring diagram is a total system diagram including the wall thermostat and air conditioner The wiring diagram is drawn so that all wiring box components are shown positionally correct 3 Before beginning the checkout procedure thoroughly read the checkout instructions in either the thermostat installation instructions or in the owners manual provided with this product Keep in mind that the wall thermostat provides a 3 minute delay between off and on cycles A 2 5 minute delay begins both as soon as the compressor cycles off and as soon as the thermostat becomes energized After completion of the 2 5 minute delay an additional 30 second delay will begin as soon as the thermostat demands cooling There is also a 30 second delay between 1 and 274 stage cooling This is to prevent both compressors from starting simultaneously To ensure that the thermostat calls for both 1 and 204 stage cooling verify that the cool setpoint is well below actual indoor temperature 4 After complying with steps 1 through 3 engage power to all systems and begin checkout procedure 5 UNIT DEPICTION FIGURES PACKAGE AIR CONDITIONER MODEL NUMBER
15. p c board H green L E D will still not remain on afte coil temperature is OK check thermister for continuity Caution may have a very high resistance Replace thermister if oppen oz Check all pin connectors 21 Check for 12 VDC to R gt thermostat and p c Check 12 VDC to pin board Replace defective parts nececcary connectors R amp B in ne B at the board See Figure 14 thermostat lt Replace p c bpard if al the above checks out Restore 12 VDC to OK and green light thermostat does not come 17 10 BLOWER LOW SPEED THERMOSTAT ON LOW FAN Note operating functions subject to thermostat time delays 115 V AC to System 1 NO est at T1 amp T5 on p c board estore pow st O E 12 VDC to GL amp B NO Check 12 VDC to R amp B NO Pectore 12 VDC at therrnostat at thermostat R D BG Oo O E E Replace thermostat 12VDC to pin connector NO Check all pin connectors and m Fic 4 ard connections from thermostat SSe CIEE ID Replace lifaline if nacessay O K 115VAC lo NO relay 3 and TS on p c Replace p c board board 5 Figure 13 Checz wiring to motor Check capacitor and motor win mge for apen ot ground Reconnect wires ot replace capacitor or motor nezcegaty 18 I D BLOWER HIGH SPEED THERMOSTAT ON HIGH FAN Note operating functions subject to thermostat time delays NO
16. refrigerant charge from system systems being serviced Remove terminal caps See 10 Figure 12 Remove wiring from compressor terminal block cut wire ties on suction line 15 Unbraze plumbing at points 411 and 12 Figure 12 protect any wiring and insulation from torch flame Remove mounting nuts and washers See 13 Figure 12 Remove compressor from unit Note Upon reassembly compressor wires shall be wire tied to suction lines to prevent excess chafing 14 ELECTRICAL FLOW CHARTS 6636 SERIES OPERATION SEQUENCE Green L E D NO Refer Checkput Light Green L E D Light Thermostat Call Indoor Blower Compressors Refer to Indoor NO NO NO Refer to 2 Refer 1o Ind Comp 2 2 Low Checkout High High Checkout ompi Operation Blower High L E D Refer 10 Rlower NO Outdoor High Blower High Refer to Comp 1 NO Comp 1 Checkout Q D Alower low FD Refer to NO Outdoor Blower Low Blower Lo 16 CHECKOUT NO GREEN L E D LIGHT FY F CIRCUIT TO THE THERMOSTAT YES Refer to 6636 Series Operatio Green L E D Light Sequence Problem is not in FY F circuit to the fhermostat N 0 115 VAC to Circuit 1 NO Restore 115 VAC power High Voltage Board to 1 Circuit D K YES If green light comes on check the evaporator coil for freeze situation Warm coiltemperature above 60 F Use jumper wire across thermister terminals on
17. to motor shaft before assembling wheel 3 Torque set screw on flat of shaft to 110 10 in 165 11 9 OUTDOOR BLOWER MOTOR REMOVAL It will be necessary to remove the top panel of the 6 unit y Remove 4 screws that attach scroll housing to side panel See 1 Figure 9 8 Disconnect wiring from motor terminal block 9 Remove scroll motor assembly from the unit 10 If at this point only the blower wheel needs replaced then remove 4 screws from inboard venturi Remove Note and replace blower wheel see note or else go to Step 6 BOTTOM VIEW Disconnect wiring at capacitor Remove 4 screws from venturi See 1 Figure 10 Remove 4 screws from motor mount bracket See 2 Figure 10 Remove motor assembly from scroll Remove blower wheel and motor mounting bracket Upon reassembly the references made on Figures 9 and 10 shall be used for proper reassembly 1 Wheel must mounted with minimum of 1 4 clearance to both venturis 2 Apply grease to motor shaft before assembling wheel 3 Torque set screw on flat of shaft to 110 10 in lbs 10 CAP TUBE REPLACEMENT Remove top panel Remove panels from end and side covering compressors and outdoor blower wheel Remove outdoor blower and housing 1 Make sure to label wires of fan motor when you take them off Be certain at this point that the refrigerant charge has been removed from the system systems being serviced Unbraze
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