6531 Series Elevator Air Conditioner Service Manual
Contents
1. OQ Run Capacitor Fan Capacitor ns QUICK TROUBLESHOOTING TIPS SYMPTOMS CAUSES Insufficient voltage to the unit wiring thermostat p c board open thermister start capacitor run capacitor start relay open overload compressor Fan runs no compressor operation Wiring thermostat fan capacitor fan motor P C board if the compressor runs Fan relay if the heating element works Nothing runs no compressor No a c voltage transformer fan no heat thermostat limit switch open heat element Air flow restrictions high ambient temperature undersized too much heat gain refrigerant system low charge compressor IF YOU HAVE NOT BEEN PROPERLY TRAINED IN REFRIGERATION SEALED SYSTEM REPAIRS DO NOT ATTEMPT TO BREAK INTO THE SYSTEM Heat or compressor runs No fan operation Compressor mins fan runs insufficient cooling VIII COMPONENT CHECKOUT THINK SAFETY other wires All switches fuses circuit breakers disconnects etc should be in this line 1 Power Supply from Commercial Utility b 1 Wire Size The power supply to the air conditioner must come through a circuit breaker or time delay fuse The power supply must be 20 amperes and 12 AWG wire minimum Any size larger wire at any time may be used and should be used if the length of the wire is over 32 feet 2 Color Code The electric power from the electric service panel s2. on p c board and Yellow on thermostat plug on p c board and on p c board S Check for an open circuit to h thermister terminals on p c board 5 n ys s compressor come on P K E Y N E Check for 120V between Replace freeze N O on compressor relay switch Replacc thermostat on p c board and white incoming power N M 5 Check compressor run capacitor Check start capacitor relay Check compressor windings for open or ground Check compressor for mechanically locked up Check for 120V between the common terminal on compressor NO YES Open wire or bad connection NO Check thermostat wiring to find open relay on p c board and the white incoming power Y Replace p c board 12 Check wire and connections from common on compressor contactor and black incoming power Compressor Runs No Fan Thermostat In Cooling Mode And Turned Down So That It Will Be Calling For Cooling NO On p c board check from G to for 24V Check for 120V between fan terminal on p c board and NO terminals amp Does At thermostat jumper NO fan come on Y E S Replace thermostat white incoming power Check for 120V between p c board fan t
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4. blower operates continuously Compressor V SEQUENCE OF OPERATIONS The 115 VAC power supply supplies line voltage to the transformer NS and the p c board 1 The transformer NS supplies control voltage to the wall thermostat R terminal When the wall thermostat calls for cooling The thermostat makes a connection R to 4 and sends a signal back from the Y terminal to energize the p c board compressor relay 1 and When the wall thermostat calls for heat completes the circuit to the compressor The thermostat makes a connection to W and sends control voltage back from the W terminal to energize the heater relay 4 and completes the circuit to thc hcating clement 6 The thermostat makes a connection to G and sends control voltage __ back fromthe terminal to energize the p c board 1 fan relay and completes the circuit to high speed on the fan motor When the heater relay 4 circuit is completed it then energizes the fan relay coil 3 and completes the circuit to high speed on the fan motor VI ELECTRICAL COMPONENTS IDENTIFICATION DESCRIPTION PART gt 5 ms o Az5285z22E Dg Sm AAO Eng gO lt lt E E O O g 42
5. indicator movement on the second test the capacitor is open Open capacitors are defective and must be replaced OPEN HIGH LOW Indicator shows no movement Needle stays to the left side If needle shows no movement after reversing the leads the capacitor is open 10 Shorted Capacitor If the capacitor is shorted the indicator will move toward and sometimes hit zero ohms and will stay there This indicates a completed circuit through the inside of the capacitor shorted Shorted capacitors are defective and must be replaced SHORT HIGH LOW Indicator moves to the right side of the scale and stays there indicating a completed circuit The capacitor is shorted Grounded Capacitor When testing for a grounded capacitor perform a continuity check between each terminal on the capacitor and the bare metal of the capacitor case Any indication of a circuit constant resistance from either terminal to case indicates a grounded capacitor Grounded capacitors are defective and must be replaced CAPACITOR OHM METER GROUNDED HIGH LOW Indicator moves to the right side of the scale and stays there indicating a completed circuit The capacitor is grounded 11 Start Capacitor Some models use a start capacitor and a start relay to give the compressor high starting torque The compressor will therefore start against normal pressure differences head pressure minus suc
6. 3 Thermister The thermister is a freeze protection device installed in the compressor relay circuit to prevent evaporator coil freeze ups This device is a semi conductor which has electrical resistance that varies with temperature The thermister cutout temperature is 31 F 3 and reset temperature is 53 F IX ELECTRICAL FLOW CHARTS Nothing Runs Thermostat In Cooling Mode And Turned Down So That It Will Be Calling For Cooling Check for 120V between black NO incoming power and white incoming power Y E S Check for 24V between 1 NO Restore 120V powcr Replace transformer and check Red on thermostat plug and B terminal on p c board for short in low voltage wiring Y E S Check for 24V between NO Jumper thermostat terminals NO Y amp B and between G amp B between RC amp Y plus RC amp G on p c board Docs unit come on Y Y E 5 5 Refer to charts Compressor or No Fan Operation Replace thermostat Open circuit in low voltage wiring open wire or bad connection 11 Fan Runs No Compressor Turn Thermostat To Cool And Turn Temperature Down So That The Thermostat Should Be Calling For Cooling Check for 24V between NO Check for 24V between 2
7. Fel RV Products Division of AIRXCEL In SERVICE MANUAL FOR 6531 SERIES ELEVATOR AIR CONDITIONERS TABLE OF CONTENTS I Warnings ree ee porn eee a eve ere s x ees cao etia e Grn a e 2 Component 2 Specifications And Unit 3 IV Wall Thermostat Operation 7330 324 4 V Sequence Of 5 VI Electrical Components 6 VII Quick Troubleshooting 7 Component 7 IX Electrical Flow 11 X Wiring Diagram e a 16 I WARNINGS IMPORTANT NOTICE WARNING SHOCK HAZARD 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 15 essential to satisfactory and safe product performance The words Should or May indicate a recommendation or advice which is not essential
8. IMUM OVERCURRENT PROTECTIVE DEVICE AMP 20 R 22 CHARGE WEIGHT ay TOM MINIMUM SUPPLY CONDUCTOR GAUGE COPPER UTILISER DES FILS 12 D ALIMENTATION EN CUIVRE MAXIMUM EXTERNAL STATIC PRESSURE 5 IN H0 UNIT WEIGHT 75 LBS 6531 692 LENGTH 22 1 8 DEPTH 18 1 8 HEIGHT 19 3 4 ACCESSORY WEIGHT 28 LBS KIT LENGTH 15 7 8 6531 692 DEPTH 16 9 32 HEIGHT 10 IV WALL THERMOSTAT OPERATION FOR 7330 324 E FAN YSTEM FAN SYSTEM AUTQ ON COOL OFF HEAT AUTQ ON COOL OFF HEAT re pee VAT DO E El SUB BASE BI METAL PLATE ON _ coop OFF HEAT 1 1 F rated differential 2 Shrouded contacts 3 Heat anticipator 15 8 amp self adjusting 90 Wiring RC Control Wiring Supply 60 ES RH or 4 Control Wiring Supply Heat 50 Y Compressor Relay Coil MO G Fan Relay Coil W Furnace COMPLETE ASSEMBLY BI METAL PLATE SCREWED 0 SUB BASE AND WITH SNAP ON COVER THERMOSTAT OPERATION SHOWS POSITION OF SWITCH 7330 324 HEAT OFF COOL ON Operation of all components is stopped Cooling fan runs continuously No compressor operation Cooling blower and compressor cycle with thermostat cycles with thermostat Cooling blower operates continuously at high speed Compressor cycles with thermostat Heating system cycles from thermostat Cooling fa operates continuously Cooling
9. and not required but which may be useful or helpful To prevent the possibility of severe personal injury or equipment damage due to electrical shock always be sure the electrical power source to the appliance is disconnected during installation 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 this unit will void the warranty may make the equipment in violation of state codes may create a hazard and may ruin the equipment COMPONENT MATCH UP l 6531B692 Package Air Conditioner 2 6531 625 Accessory Kit Optional SPECIFICATIONS AND UNIT IDENTIFICATION PACKAGE AIR CONDITIONER MODEL NUMBER BREAKDOWN 6 5 3 1 6 9 2 1 12 VDC Control Voltage 2 24 VAC Control Voltage Model Series 8 No Start Kit 9 Start Kit Included Revision Letter 6 Panasonic Compressor s 7 Sanyo Compressor s 8 Tecumseh Compressor s SPECIFICATIONS USE THERMOSTAT MODEL 7330 324 SUPPLIED WITH ACCESSORY KIT 6531 625 115 60 1 VOLTS AC HZ PHASE RLA 69 COMPRESSOR MOTOR THERMALLY PROTECTED LRA 340 ELECTRIC HEATER FLA 125 BLOWER FAN MOTOR 1 3 H P FLA 2 9 MINIMUM CIRCUIT AMPACITY AMP 20 MAX
10. ct all electrical power to the air conditioner b Discharge the capacitor with a 20 000 ohm approx 3 watt resistor or larger You may discharge capacitors with a standard volt meter if you use a scale over 500 volts and touch the leads one lead to each side of the capacitor the volt meter will discharge the capacitor d Identify and disconnect the wiring from the capacitor e Set and zero the ohm meter on the highest scale When testing for a good open or shorted capacitor perform the following checks Place the ohm meter leads across the capacitor terminals one lead on each terminal and perform a continuity test Then observe the action of the meter needle or indicator Reverse the leads and test again The result should be the same Note If the capacitor had not been properly discharged a false reading could be indicated on the first test Always test several times reversing the leads with each test This will verify the capacitors condition Good Capacitor If the capacitor is good the indicator will move from infinity the left side up towards zero ohms and slowly return back to infinity Reverse the leads and test again The result should be the same CAPACITOR OHM METER Indicator sweeps back and forth as shown above Capacitor is good Open Capacitor If the capacitor is open the indicator will show no deflection or movement Reverse the leads and test again If there is no
11. erly it can be checked in the following manner 1 sure the motor leads are connected to the proper points a The black wire from the motor connects to a black wire inside a wire nut then the black wire connects through the disconnect plug to the selector switch The red wire from the motor connects to a red wire in a wire nut then the red wire connects through the disconnect plug to the selector switch b The white wire from the motor connects to a white wire in a wire nut then the white wire connects through the disconnect plug to the thermostat The brown wires from the motor connect to the fan capacitor 2 To check the motor winding resistance carefully check the resistance between each of the wires and ground preferably a copper refrigerant tube for a good connection These readings must be infinity Any continuity means the windings are grounded If there is a reading of 0 between any two leads the motor is shorted and is no good If there is a reading of infinity between any two leads the winding is open and the motor is no good 6 Relays The low voltage relays are used in the control circuits to close or open a set of high voltage contacts When this happens it either makes or breaks a circuit To check the relay you must first 1 shut the power off to the unit 2 take the line voltage wires off the relay 3 apply 24 volts to the coil side of the relay and 4 take an ohm meter and check to see
12. erminal black wire coming from motor and white wire on compressor run capacitor Replace p c board NO Wa tt lt Check fan motor run capacitor and fan motor Check wiring and all connections 13 Check low voltage wire and connections for open Fan Runs No Heat Thermostat In Heating Mode and Turned Up So That It Will Be Calling For Heat Check for 120V between a orange wire to heat element Check wiring and connections and white wire on limit switch to heat element Check for 120V Check for 120V across heat element limit switch Y Replace limit switch With amp clamp meter and check heat check for amperage on element and air flow orange wire Replace heat element 14 Heat Runs No Fan Thermostat In Heating Mode And Turned Up So That It Will Be Calling For Heat Check for 120V between fan NO terminal on p c board and white Check for 120V between terminal 3 on fan relay and white incoming power NO incoming power Y E S Check for 120V between p c board fan terminal black wire coming from motor and white wire on compressor run capacitor Y E Check fan motor run capacitor and fan motor Check wiring and all connections 15 Uma Check for 120V between terminals 3 amp 5 on fan rela
13. hould be delivered through a 3 conductor cable and the Service Technician should check to be sure the color code is correct The electrician probably installed the cable with the colors according to code but don t bet your life on it a The wire with black insulation is the hot wire and there should be 115 volts domestic USA between it and either of the The wire with the white insulation is the neutral There should be 115 volts domestic USA between the neutral and the hot black wire but there should be 0 volts between the neutral and the ground the green wire or the frame of the air conditioner There must be no switches fuses disconnects etc of any kind in the neutral wire The third wire may be covered with green insulation or it may be a bare metal wire It is the ground wire There must be 115 volts domestic USA between this wire and the hot black wire and 0 volts between it and the neutral white wire The ground wire must be securely fastened to the air conditioner cabinet A green headed screw is provided for this purpose 3 Voltage The voltage electrical pressure at the unit should be 115 volts domestic USA and all electrical components will perform best at the correct voltage However the voltage will vary and the air conditioning system will perform satisfactorily within plus or minus 10 of the rated 115 voltage domestic USA Therefore the voltage has to be between 103 5 volts and 126 5 volt
14. if the contacts open and close 7 Transformers The transformer is used in the circuit to convert 115 VAC and step it down to 24 VAC To check the transformer simply take a voltmeter and check for 24 VAC between the red and blue wires coming from the transformer 8 Heating Element The heating element is a resistance heater of 1600 watts 5600 capacity and is connected across the line when the selector is set for heating and the thermostat is calling for heat The current draw of the heater element only will be 13 9 amperes at 120 volts domestic USA models 9 Limit Switch The limit switch is a safety switch and is mounted in the heating element frame It will open and break the circuit on temperature rise in case the air flow through the heater becomes low enough to cause the heater to overheat 10 Run Capacitors The purpose of the run capacitors is to give the motors starting torque and to maintain high power factor during running The run capacitors are always connected between the start and run or main terminals of the motor Capacitor Check There are several capacitor test devices available The ohm meter is one of them The ohm meter cannot verify a capacitors MFD microfarrad value However the following procedures will show you how to use an ohm meter to determine if the capacitor is good open shorted or grounded Before testing any capacitor always perform the following procedure a Disconne
15. nnected in series with the common terminal If the switch opens it will cut the power to the compressor motor The switch will open as the result of either or both of two conditions that could be harmful to the compressor 1 High Amperes Current The switch contains a heater which increases in temperature as the current increases The higher temperature warps the switch and will cause it to open before the windings reach a dangerous temperature 2 High Temperature Thermal The switch is clamped tightly against the compressor housing and located close to the windings Therefore as the windings reach a higher temperature it takes less current to cause the switch to open As can be seen the switch is always affected by a combination of current to the compressor and winding temperature 5 Fan Motor air conditioning unit has one double end shaft fan motor On one shaft end is mounted a centrifugal or squirrel cage blower which draws air return air out of the recreational vehicle and blows the conditioned air down into the recreational vehicle On the other shaft end is mounted an axial flow or propellor type fan which circulates outdoor air through the condenser coil An important step in installing a replacement fan motor is to check the direction of rotation before it is installed On all models the condenser fan pulls the air through the coil Fan Motor Check Procedure If a fan motor refuses to perform prop
16. s 2 Power Supply Generated By On board Motor Generator If the power supply for the recreational vehicle is supplied by an on board motor generator its wiring may be identical to the commercial power described above There are however some motor generators on which both the current carrying leads are insulated from the ground That is to say there is no grounded neutral so there will be 115 volts domestic USA between the black and white leads but there will be 0 volts between either lead and ground WARNING service technician must keep in mind when checking to make sure that the power is turned off check only between the hot black lead and the neutral white lead The black lead could still be hot even though there is 0 volts between it and ground 3 Compressor Motor The compressor motor is located inside the hermetic compressor housing and is therefore not accessible for service or visual observation in the field However the motor winding condition can be analyzed by using an ohm meter Be sure to remove all the leads from the compressor terminals before making this check 1 If the resistance between any two terminals is 0 ohms the motor windings are shorted 2 If the resistance between any terminal and the compressor housing is anything but infinity the winding is grounded 4 Overload Switch Mounted on the outside of the compressor housing is a two terminal Overload switch The switch is co
17. tion pressure even when shut down for a short period of time The start relay will disconnect the start capacitor when the motor reaches approximately 75 running speed Notice the resistor which is soldered to the terminals of the start capacitor The resistor is there to discharge the capacitor after the relay disconnects it from the circuit This resistor must be in place or the capacitor will discharge through the relay when the compressor is shut down and in doing so will damage the relay contacts 12 Start Potential Relay The start relay consists of 1 Normally closed contacts internally between terminals 1 and 2 which switch in the start capacitor in parallel to the run capacitor during shutdown and then switch out the start capacitor when the motor reaches approximately 75 normal running speed 2 high voltage coil internally between terminals 5 and 2 to actuate the contacts The coil is too weak on line voltage to actuate the contacts but it is connected in series with the start winding and it gets the generated voltage of the start winding portion of the compressor motor This generated voltage is much higher than line voltage and varies with the speed of the motor Therefore since the relay is designed to open the contacts at 7596 of normal running voltage measured between terminals 5 and 2 the contacts will open thus disconnect the start capacitor at approximately 7596 of normal running speed 1
18. y n mi lt oz Check black wire and connections from 5 on fan relay to heat relay Check for 120V between orange and white wires on fan relay N Y E Check wiring to S orange and white wires and connections from the fan relay Replace fan relay X WIRING DIAGRAM RED co COMPRESSOR BRN 12 WIRING USED WITH WIRING USED WITH on MED M NTIAL M X 1 STARTING RELAY 1 STARTING RELAY BRN WHT PANS WHT WHT RUN RUN RED 1 REDI BLK 1 BLK 1 i a TRANSFORMER 1 START 1 pi 5 i RELAY z z i 8 N 15 m 1 RED WHT 1 ORG WHT WHT LIMIT LIMIT T BLK 2 START HEATER CAP RELAY E MEE oe tcl 2 WHT es oc Ed FACTORY WIRING Su FAN T FIELD WIRING g RELAY BOARD TRACE H FREEZE 4 SWITCH GRN gt YEL 2 120 60 Hz PH 19768176 T STAT PLUG SUPPLY WIRING 16 Fel RV Products Division of AIRXCEL Inc RV Products A Division of Airxcel Inc P O Box
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