SERVICE MANUAL FOR 6636A & 6636B SERIES
Contents
1. 17 15 Electrical Flow 18 1 WARNINGS IMPORTANT NOTICE These instructions are for the use of qualified individuals specially trained and experienced in installation of this type equipment and related system components Installation and service personnel are required by some states to be licensed PERSONS NOT QUALIFIED SHALL NOT INSTALL NOR SERVICE THIS EQUIPMENT NOTE The words Shall or Must indicate a requirement which is essential to satisfactory and safe product performance The words Should or May indicate a recommendation or advice which is not WARNING SHOCK HAZARD To prevent the possibility of severe personal injury or equipment damage due to electrical shock always be sure the electrical power to the appliance is disconnected CAREFULLY FOLLOW ALL INSTRUCTIONS AND WARNINGS IN THIS BOOKLET TO AVOID DAMAGE TO THE EQUIPMENT PERSONAL INJURY OR FIRE WARNING Improper installation may damage equipment can create a hazard and will void the warranty The use of components not tested in combination with these units will void the warranty may make the equipment in 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 3 6795 4351 35 t2. RV Products A Divis nt cf A RXCFEI iz SERVICE MANUAL FOR 6636 amp 6636B SERIES TWO TON HIGH EFFICIENCY PACKAGED AIR CONDITIONERS TABLE CONTENTS 1 Warnings amp Component 2 2 Unit 3 3 Thermostat Operation amp 4 4 Thermostat Checkout ee eet OR EX ee NR Ue e RU AUR 5 5 Unit Depiction 5 6 Blower Performance 7 7 Wiring Diagrams Electronic Thermostat amp A C Unit 7 8 Wirebox Component Checkout 6636A 5 10 8A Wirebox Component Checkout 6636B 11 9 Indoor Blower Motor 1 12 10 Outdoor Blower Motor 1 14 11 Cap Tube 15 12 Evaporator Coil 16 13 Condenser Coil 17 14 Compressor
3. O Beby High Speed 4 1 115 V Common 1 2 Powsr Lead OD Low Speed r 9 e o fel el lt Supply BLACK WHITE BLACK WHITE dene CIRCUIT CIRCUIT 2 emana 11 Freeze Switch amp Exclusion Relay Cooling Compressor 2 Compressor 1 FIGURE 14 FY Freeze Switch amp Exclusion Relay 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 9 INDOOR BLOWER MOTOR It will be necessary to remove the top panel from the unit Remove screws that attach the blower housing to the end panel Disconnect wiring from motor terminal block and capacitor Remove scroll motor assembly from the unit Remove 3 screws from motor mount bracket See 2 Figure 7 REMOVAL Note 12 Remove motor assembly from scroll Remove blower wheel and motor mounting bracket Upon reassembly the references made on Figures 7 and 8 shall be used for proper reassembly Section 1 Section 2 Section 3 SIDE VIEW SECTION 4 SECTION 2 SECTION 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 i
4. Replace fuse if only T12 Re lace PS board amp TIS speede are and fure if both high energized amp low speeds powered from the pc board Check wiring to O D blower Check capacitor Check motor for open or ground Rewire to motor or replace components as necessary 25 1976 326 8 05 Psp RV Products A Divi n cf A RXCFEIL ag RV Products A Division of Airxcel Inc P O Box 4020 Wichita KS 67204
5. C Supply Grounded Terminal T8 System 2 L2 power to switching relay and O D blower relay high speed Supply Grounded BLACK WHITE BLACK WHITE Terminal 41 CIRCUIT 2 10 Green LED Light Indicator Systam 1 Line Power OK Freeze Switch Is Closed 12 VDC From Therma stat OK T12 115V L1 Power Output To OD Blower Relay High Speed Energizes DD Blower High Speed Relay amp Switching Relay Power Comes Fram Compressor 2 Relay T11 115V 1 Power Output Ta DD Blower Low Speed System 1 T4 11 Powers From Systern 1 Compressor Energizes OD Blower Relay Low Speed On Terminal Board Supply Crounded Terminal 8A WIREBOX COMPONENT CHECKOUT FOR 6636B SERIES T16 12 VDC From 12 VDC lt gt From Y2 Dn Therrnostat On Thermostat Compressor 2 Relay 12 VDE Coil Mak es Cutt Circuit 1 To Corapress or Tz 12 VDC Fram 1 Dn ostat To Cornpressor 1 Relay 12 VDE Coil Makes Circuit 2 To Cornpress or 2 T 115V Line 11 Power Outp To ID Blawer Law Speed System 1 Power 11 To Indoor Blower Relays Also Power To Exclusion Relay Outdoor Blower 115 To ID Blower High Speed TS System 1 Common Lead L2 To OD Blower Relay Low Speed Through Normally Z Closed Contactar On Switching Relay ra 2 Common L2 Power To Swat hing Relay Aml OD Blwei
6. 1 verify that the connectors are properly aligned 2 do not use excessive force when joining the connectors 3 verify that the connectors have snapped together on both sides The thermostat umbilical attaches to the unit with a rain tight fitting To install remove the ring nut from the rain tight fitting and insert the wire end and fitting into the hole in the wirebox side The ring nut will now slide over the wire end and reinstall onto the rain tight fitting threads Tighten securely The wire end plugs into the receptacle on the wirebox printed circuit board Insure that the plug snap locks into the receptacle 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 thermo
7. 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 2 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 BREAKDOWN FOLLOWS Sub Mounted Unit 24 000 BTU Non Exhaust High Efficiency 8 7 1 12 VDC Control Tecumseh Compressor PTCR Start Capacitor FIGURE 1 6 PACKAGED AIR CONDITIONER BLOWER PERFORMANCE DATA TEST CONDITION 115 VAC 60 HZ 1 PHASE DRY COIL EXTERNAL STATIC PRESSURE INCHES OF WATER COLUMN E m aso eer 599 563 ames ses 375343 357 342 352322342 290 287 25 a 25 LOW SPEED OPERATION EXTERNAL STATIC PRESSURE INCHES OF WATER COLUMN scm asr feon ont mr eram mt re r e en ames 428 482 405 450 4 41 3 98 3 81 3 67 E HM HIGH SPEED OPERATION 7 WIRING DIAGRAMS Diagram 1976G119 Electronic Wall Thermostat Assembly 12 VDC FAN SWITCH HI AUTO LD LD ON HI SYSTEM SVITCH 181 STAGE CDOL 6636 3451 WALL THERMOSTAT ASSEMBL Y HEAT 2nd STAGE COOL TO FURNACE 6795B435 LIFELINE WIRING DIAGRAM 6636 MODEL PAINTED C
8. C controlled heating and air conditioning systems The thermostat is designed to operate 12 VDC controlled heating and air conditioning systems The thermostat must be operated from a 12 VDC power source The thermostat can control one stage heating and two stages of cooling The thermostat used to operate the 6636 series air conditioner must be capable of controlling two stage cooling systems Maximum thermostat output for any load including the furnace control wire must not exceed one amp IMPORTANT Current draws in excess of one amp or shorting any thermostat wires will cause permanent thermostat failure The installer must provide the power source used to operate both the thermostat and its control circuits This power source must provide one amp of continuous current at 12 VDC The thermostat is pre wired at RV Products with two quick connect electrical receptacles There is one 9 pin receptacle carrying the 8 control wires required to operate the air conditioner and a 3 pin receptacle carrying the two power supply leads and the one furnace control lead The thermostats 9 pin receptacle mates with a receptacle on one end of the RV Products 35 pre wired thermostat harness See component match up sheet for harness part number and description The thermostat 3 pin receptacle has no mate in either the thermostat harness wiring or the thermostat package Should the installer desire a total plug in system then the mate for th
9. IRCUIT CONTROL BOARU CIRCUIT 2 CIRCUIT 1 THERMISTOR FREEZE SWITCH COMPRESSOR 2 START DEVICE COMPR e u s d 5455 8888 x v sou QAO INDOOR BLOWER 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 IDENTIFIED TERMINAL WIRING DIAGRAM FOR 6636B MODEL FROM 2 STAGE WALL THERMOSTAT ASSEMBLY GOMPRESSOM STAMT COMPRESSOR RUN CAPACITOR 30 370 G 1 P T E R e CDMPRESDR RELAY 2 PDMPREGEUR CAPACITOR 2 COMPRESSOR AUN CAPACITOR 30 370 2 COMPRESSOR P T D R 2 COMPRESSOR RELAY PRINTED CIRCUIT CDNTRDL BDAAD BRN WHT CAPACITOR 12 87370 QuTOOOR BLOWER 4 IDENTIFIED TERMINAL NOTE HIGH VOLT WIRING 115 V SHOWN BOLD Lov 12 19751119 VOLT WIRING SHOWN FINE 8 FOR 6636 SERIES Grean L E D Light FIGURE 13 Indicator System 1 line powar OK Freeze Switching Relay Swilches O D blower tp high epeed with i switch Is closed 12 Comp 2 oparalion xu DE Cel VDC from thermostat P OK Exclusion relay energized from System 1 115V power closes FF circ
10. all pin connectors and connections from thermostat Replace lifeline if necessary GL amp B pn p c board See Figure 14 0 115 VAC to contact NO relay 3 and T5 on p r Replace p c board board See 13 Check wiring to motor Check capacitor and motor windings for open or ground motor as neccesary 20 LD BLOWER HIGH SPEED THERMOSTAT ON HIGH FAN Note operating functions subject to thermostat time delays NO 115 VAC to System 1 T1 amp T5 on p c board BBWS Check 12 VDC tp NO 12 VDC to GH amp B at R amp B at Restore 12 VDC thermostat thermostat B 9 0 0 K K Replace thermostat 12 VDC to pin connectors GH amp NO on p c board See Figure 14 Check all pin connectors and connection from thermostat Replace lifeline if necessary 115 VAC to N O contact NO pn relay 4 and T5 on Replace p c board board See Figure 13 Check wiring motor Check NO Reconnect wiring or and motor replace capacitor or windings for open or ground mptpr if necessary 21 COMPRESSOR 1 CHECKOUT THERMOSTAT CALLING FOR COMPRESSOR Note operating functions subject to thermostat time delays 145 VAC tn system 1 NO Restore power also to T1 amp T5 on p c board PASTAS power NO Green L E D light FY continuity NO Check 12 VDC NO to RRR o
11. anels from end and side covering compressors and outdoor blower wheel Remove outdoor blower and housing A Make sure to label the wires of the 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 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 15 12 REPLACEMENT Remove top and side panels next to evaporator 5 Remove screws 4 45 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 FIGURK 12 16 13 CONDENSER 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
12. hermostat cable with connector plugs specifications for model number breakdown and identification 2 6636 3451 Electronic 12 VDC Wall Mounted Thermostat This thermostat is pre wired to two electrical connectors Both the thermostat supply and control wiring can be quickly attached plugged in to the thermostat for termination at both the air conditioner and electronic thermostat 2 UNIT SPECIFICATIONS 66364871 amp 66368871 MODELNUMBER SERIAL NLIMBER FOR OUTDOOR USE USE THERMOSTAT 6636 345 ELECTRICAL RATINGS 115 VAC 60 HZ 1 PHASE CIRCUIT 1 CIRCUIT 2 RLA COMPRESSOR RLA 1450AZ2 1 453 LRA LRA NEN FLA ID BLOWER MOTOR DATA 1 0 0 BLOWER MOTOR DATA ta gt 170 MINIMUM CIRCUIT CAPACITY MAXIMUM OVERCURRENT PROTECTIVE DEVICE R 22 CHARGE WEIGHT 0 25 MIN SUPPLY CONDUCTOR GAUGE COPPER UTILISER DES FILS 25 40 410 222 D ALIMENTATION EN 40 63 CURVE 40 63 25 40 N a WEIGHT 200 LBS LENGTH DEPTH HEIGHT RV PRODUCTS A DIVISION OF AIRXCEL INC WICHITA KS 57204 3 THERMOSTAT OPERATION AND SPECIFICATIONS THERMOSTAT OPERATING AND WIRING REQUIREMENTS The 6636 series air conditioner is designed to be operated from an RV Products electronic wall mounted thermostat See component match up sheet for thermostat part number and description The thermostat is designed to operate 12 VD
13. inals and 2 amp on p c board Also connections from thermostat T10 amp TSB See Figure 14 Replace lifeline if aecessary NO Replace relay if 12 VDC is present and relay won t rlose or if relay iz welded Check compressor start device Check for proper wiring to NO 415 compressor 2 Check compressor Reconnectwiring or replace run capacitor Check compressor components as necessary motorwindings for open or ground 23 CHECKOUT OUTDOOR BLOWER LOW SPEED Outdoor blower system 1 red L E D low speed See Figure 13 Line volts 115 VAC 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 pn p c board Replace p c board Check wiring to O D Rewire to motor or blower Check capacitor replace Check motor for ground or components as open necessary 24 CHECKOUT OUTDOOR BLOWER HIGH SPEED Outdoor blower system 2 red LED 3 high speed See Figure 13 from compressor 2 relay 115 VAC to T12 amp T13 on NO p c board Replace p c board Line volts 115 VAC to terminal NO Refer to compressor 2 T8 amp T9 on p c board L1 line power checkout K K Remove motor leads Red amp block wires from p c board and DR check p c board for 115 VAC to Check both motor speeds at the same time equippe T12 amp T13 High Speed amp T13 Low Speed If No
14. is connection will have to be purchased separately Both the receptacle and the pins are manufactured by AMP Aircraft Marine Products Inc Harrisburg PA In most cases the parts can be obtained through a local supply house The AMP part numbers are 1 3 pin male receptacle 7 480700 0 2 female pin for male receptacle 350218 1 Should the installer desire to hard wire this connection rather than purchasing the receptacle the three pin connector can be cut from the wire ends the wires stripped and spliced to complete the required connections For further wire identification and function reference Chart 2 CHART 2 WIFE FUNCTION COLOR each wire connects with 12 VDC Supply Lead BLUE 12VDC Supply Lead WHITE Furnace Control Wire engages furnace IMPORTANT When using wire nuts to complete electrical connections always apply a U L approved electricians tape and secure the wire nuts to the wires in a workmanlike manner THERMOSTAT HARNESS RV Products produces a pre wired 35 thermostat wiring harness for this system See component match up sheet for harness part number and description This harness consists of the eight wires required for operating the air conditioner and quick connect receptacles for both the thermostat and the air conditioner connections At the thermostat the connection is completed with a square 9 pin receptacle that slides together and snap locks in place When making this connection
15. n Rectore 12 VDC 12 VIC 10 on thermostat Remember time delayej Ihermpslal Check all pin terminak and connectors to thermostat Replace H he Cessaly 115 VAC to system 1 Restore 115 VAC 12 VD to connectors Y amp R p c board also 12 amp ISA K See Figure 14 K Green pm ight ight On K Replace relay if If open refor 1o 12 ls B eco nt NO Freeze censor 0 ae and relay will not Check compressor 71 cloned sensor checkoul close or il relay operation relay is welded 0 Check terminals and all Check compreesor 1 device connectlons from thermostat fo p c Reconnect wiree Check for proper wiring to Board Check 17 VDC R amp B or replace compressor Check compressor al p c board Sea Figure 14 components run capacitor Check motor as necessary windings for ppen ar ground Everything above checks oul replace p c board 22 COMPRESSOR 2 CHECKOUT THERMOSTAT CALLING STAGE 2 COOLING ONLY Note All Operating Functions Subject To Thermostat Time Delays Check 115 to cyctem 2 NO fo compressor 2 relay and common Z2 Restore 115 VAC 4 System 1 compressor operating See debe 1 K O K NO Replace thermostat if system 2 should be calling and is not according to operation manual 12 VDC to Y2 amp at thermostat 12 VDC to pin connectors NO Cheek all pin term
16. n 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 1 Wheel must mounted with a minimum of 5 16 clearance to scroll sides 2 Apply grease to motor shaft before assembling wheel 3 Torque set screw on flat of shaft to 110 10 in 165 13 10 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 be mounted with a 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 11 Remove top panel Remove p
17. stat 3 pin receptacle before removing the 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 the following A tools have been removed from the equipment B wiring is attached routed and properly secured C panels both mechanical and electrical are 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
18. t 115 VAC to Circuit NO Restore 115 VAC 1 power to 1 Circuit If green light comes on check th YES evaporater coll for freeze situation Warm coil temperature above 6D F Use jumper wire acrose thermister terminals on p c board If green L C D will still not remain on after coi temperature is OK check thermister for continuity Caution It may have avery high resistance Replace thermister if open oz Check for 12 VDC to Check all pin connectors Check 12 VDC to pin connectors R amp B in Tra board See Figure 14 at thermostat lifeline SM pir board Replace efective parts as necessary B at the thermostat Beplace p c board if al Restore 12 VDC to the above checke out thermostat OK and green light dopes not come On Model 6636B the Green L E D has some different functions 1 If the light is on solid then everything is OK If the light is blinking slowly the unit is in a 3 minute time delay 3 If the light is blinking fast there is either no line voltage to Circuit 1 or the freeze thermistor is open 19 LD BLOWER LOW SPEED THERMOSTAT ON LOW FAN Note operating functions subject to thermostat time delays 115 VAC to System 1 NO T1 amp T5 on p c board 0 12 VDC to GL amp BL__NO Check 12 VDC to R amp B NO Restore 12 VDC at thermpstat at thermostat K 12 VDC tp pit connector NO Check
19. uit to thermostat unless freeze switch is Red light indicates System 2 comp Relay has made and blower running on high speed System 2 power Indper Blower High 12 VDC coil 1 pole relay energized from on the thermostat G OLOMTI OY makes Circuit 1 to high P3 bl ion speed motor tap 2 12 VDC from Y 1 pn tharmpstat tp WARNINE Law T 1 115V line L1 Comp 1 relay power L1 Power from E town 97 output to O D blower lo System 1 comp 12 VDG ane Wi 12 VDC coil makes Circuit 2 to Comp 2 Red light indicates O D speed System 1 Energizes blower from B relay low speed term board thermostat T5 System 1 comman lead Lz to O D blower relay low speed through normally elosed contactor switching relay 1 115V comp power lead putput T10 12 VDC from blower high or Y2 on thermostat to Comp 2 relay See Ti Systemi1 O D 712 115V line 14 power L1 tp blower high speed power putputte indoor blower relay and switehing blower relay Indoor blower Low relays high and relay power comes high speed O KS 12 VDC coil 1 low Alsn power fc from 2 relay pole relay energized exclusion from GL on the thermostat makes 4 Clreult 41 to low speed mptor tap a
20. will have to go back to the same locations on the new coil Unbraze discharge and liquid lines at points 2 and 9 Figure 12 Remove condenser coil 14 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 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 17 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 15 ELECTRICAL FLOW CHARTS 6636 SERIES OPERATION SEQUENCE Green L E D NO Refer Checkout Light No Green L E D Light Thermostat Call Indoor Blower Compressors Refer to Indopp N2 Refer fo Indop Comp 72 H Refer to 2 Low Checkout ligh High Checkout Operation O D Blower lligh L E D Refer to b Outdoor High Blower lligh Refer to Checkout Blower Low L E D Refer to NO Outdoor Blower Low Blower Low 18 CHECKOUT NO GREEN L E D LIGHT FY F CIRCUIT TO THE THERMOSTAT 3 YES Refer to 6636 Series Operatio Green L E D Light Sequence Problem is not in FY F circuit to the thermosta
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